Lower Back Door: Disassembly

REMOVE REAR MAT SET PLATE
1. Remove the 5 screws.
2. Using a screwdriver, remove the rear mat set plate.
  HINT:
  
  Tape up the screwdriver tip before use.
  
  Fig 1: Removing Rear Mat Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR TRIM
1. Insert a screwdriver between the door and the door trim to pry out.
  HINT:
  
  Tape up the screwdriver tip before use.
2. Remove the door trim.
  
  Fig 2: Removing Back Door Trim
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOWER TORSION BAR
1. Remove the rear bumper. (See COMPONENTS )
2. Remove the 4 bolts and the lower torsion bar as shown in Fig 3 .
3. Remove the torsion bar guide.
  
  Fig 3: Removing Lower Torsion Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR INSIDE HANDLE
1. Remove the screw and the back door inside handle.
2. Remove the spacer.
  
  Fig 4: Removing Back Door Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK CONTROL
1. Remove the 2 screws.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
2. Disconnect the door lock control cables, then remove the back door control.
REMOVE SERVICE HOLE COVER

Fig 5: Removing Back Door Lock Control
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not tear the service hole cover.
REMOVE KEY CYLINDER
1. Disconnect the connector.
2. Remove the 2 bolts and the key cylinder.
  Torque: 5.0 N.m (51 kgf.cm, 44 In.lbf)
  
  Fig 6: Removing Key Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK
1. Disconnect the control cables from the clamps.
2. Using a Torx wrench, remove the 6 screws and the back door locks.
  Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  
  Fig 7: Removing Back Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of assembly, please refer to the following item.
  
  Apply MP grease to the rotating parts of the door lock.
3. Employ the same manner described above to the other side.
  
  Fig 8: Identifying Back Door Lock Greasing Points
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR LAMP ASSEMBLY
1. Disconnect the connector.
2. Remove the 6 nuts.
3. Using a screwdriver, remove the rear lamp assemblies.
  HINT:
  
  Tape up the screwdriver tip before use.
4. Employ the same manner described above to the other side.
  
  Fig 9: Removing Rear Lamp Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TAIL GATE STAY
1. Using a Torx wrench, remove the 2 screws and the tail gate stay.
  Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  
  Torque: 17,5 N.m (178 kgf.cm, 13 ft.lbf)
2. Employ the same manner described above to the other side.
  
  Fig 10: Removing Tail Gate Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002