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Rear Door

Body and Frame › Doors, Hood and Trunk
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Rear Door Carrier Plate - Installation15 steps
ℹ NOTE
The window regulator is not serviceable. The new carrier plate will come equipped with the regulator assembly installed.
ℹ NOTE
All the lock rods are color coded to help identify the location for the particular lock rod.
ℹ NOTE
The following illustration shows a typical door harness connector.
ℹ NOTE
Place the glass in the full down position in order to access the window regulator.
ℹ NOTE
Cycle the door lock, open with interior and exterior door handles and operate the power window to make sure everything is working properly and binding exists.
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  1. Engage the latch presenter plate tab (2) onto the rear exterior door handle stud.
  2. Position the wire harness (5) through the opening in the front shutface of the door.
  3. Seat the carrier plate assembly fully onto the door and install the ten bolts (4).
  4. Tighten the bolts to 7 Nm (60 in. lbs.).
  5. Install the screws (1) securing the door latch to the door shut face and tighten screws to 7.5 Nm (65 in. lbs.).
  6. Install the presenter screw (2) and tighten to 7.5 Nm (65 in. lbs.).
  7. Connect the electrical connector and secure the grommet (1) back over the connector/retainer and seat the connector into the pillar fully.
  8. Tighten the rear nut (1) to the exterior handle and to 5.5 Nm (50 in. lbs.).
  9. Install the door plug (2) to the door.
  10. Push the glass down and seat into the regulator liftplate (2) fully.
  11. Pull up on the glass and make sure that it is secure.
  12. Seal the glass disconnect holes with a suitable foam tape or equivalent.
  13. Install the inner belt molding and seat fully.
  14. Install the trim panel to the door. Rear Door Trim Panel - Installation
  15. Connect the negative battery cable to the battery.
Rear Door - Installation7 steps
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  1. Carefully position the door (2) to the upper (1) and lower (3) hinges using a suitable lifting device.
  2. Loosely install the nuts (4) to the door studs and hinges at the B-pillar.
  3. Align the door to the body using the reference marks made during the removal procedure.
  4. Tighten the hinge to door nuts to 36.5 Nm (27 ft. lbs.).
  5. Connect the door harness electrical connector (1) to the body connector (2) at the B-pillar.
  6. Connect the negative battery cable.
  7. Adjust the door as necessary.
Rear Door - Removal5 steps
ℹ NOTE
Use a grease pencil or equivalent, mark the location of the upper (1) and lower (3) hinges on the door (2) for alignment during installation.
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  1. Loosen the battery terminal nut and use a battery terminal removal tool (2) to disconnect the negative battery cable from the battery (1).
  2. Disconnect the door harness electrical connector (1) from the body connector (2) at the B-pillar.
  3. Support the rear door with a suitable lifting device.
  4. Remove the nuts (4) attaching the door (2) to the upper (1) and lower (3) hinges.
  5. Carefully remove the door (2) from the vehicle.
Rear Door Carrier Plate - Removal17 steps
△ CAUTION
Do not attempt to remove the trim panel the conventional way. This door panel has hooks holding it to the door rather than push pins. Carefully follow these instructions in order to prevent unnecessary damage to the trim panel.
ℹ NOTE
Place the glass in the full down position in order to release the glass from the window regulator lift plate. If the glass is released from the lift plate in any other position other than full down, the carrier plate will need to be removed in order to re-position the regulator cable onto the guides and place the lift plate into the full down position for correct installation of the glass.
ℹ NOTE
The following illustration shows a typical door harness connector.
△ CAUTION
Do not force the locking tab past the connector body, as damage to the connector may occur.
ℹ NOTE
The window regulator is not serviceable. The new carrier plate will come equipped with the regulator assembly installed.
ℹ NOTE
All the lock rods are color coded to help identify the location for the particular lock rod.
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  1. Remove the trim panel from the door. Rear Door Trim Panel - Removal
  2. Rotate the inner belt molding outboard while pulling up to disengage the retention tabs and remove the molding.
  3. If required, reinstall the regulator handle or window switch to enable lowering of the glass (1) for access to the glass attachment clips (2)
  4. Position the glass into the full down position.
  5. Access the window regulator through the hole in the carrier plate. Disconnect the window regulator (2) from the door glass (1).
  6. Raise the glass (1) into the full up position and secure in place using tape or equivalent.
  7. Remove the door plug (2).
  8. Loosen the rear exterior handle nut (1).
  9. Peel the A Pillar grommet (1) off of the connector/retainer and move it up the wire harness.
  10. Grasp the wire harness (2) by the convolute section of the grommet and gently pull the wire harness down towards the floor to expose the connector lock tabs.
  11. While still pulling down on the harness, use a small slotted screw driver (3) to gently push one of the top lock tabs until the lock feature is flush with the connector/retainer body.
  12. Repeat the step 3 for the remaining top lock tab.
  13. The connector should now be able to rock out of the sheet metal hole without causing any damage to the connector or sheet metal.
  14. Remove the latch screws (1) and the presenter plate screw (2) securing the door latch to the door shut face.
  15. Remove the ten bolts (4) from the carrier plate (2).
  16. Remove the electrical connector (5) from the door.
  17. Remove the carrier plate (1).
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
CARRIER PLATE - REAR DOOR📷 18
CAUTION: Do not attempt to remove the trim panel the conventional way. This door panel has hooks holding it to the door rather than push pins. The door module must be removed as an assembly. Carefully follow these instructions in order to prevent unnecessary damage to the trim panel.
1. Loosen the battery terminal nut and use a battery terminal removal tool (2) to disconnect the negative battery cable from the battery (1).
2. Remove the trim panel from the door, see REMOVAL.
3. Remove the door plug (2). 4. Remove rear exterior handle nut (1).
5. Access the window regulator through the hole in the carrier plate. Disconnect the window regulator (2) from the door glass (1) and support the glass.
6. Remove the three screws securing the door latch to the door shut face.
7. Disconnect the door harness electrical connector (1) from the body connector (2) at the B-pillar.
8. Remove the 9 screws (3) from the carrier plate (2). 9. Remove the electrical connector (1) from the door (4). 10. Remove the carrier plate (2) from the door (4).
NOTE: The window regulator is not serviceable. The new carrier plate will come equipped with the regulator assembly installed.
NOTE: All the lock rods are color coded to help identify the location for the particular lock rod.
11. Disconnect the inside lock rod from the latch.
12. Disengage the grommet (2) and remove the inside lock rod (1) from carrier plate (3).
13. Disconnect the interior handle lock rod from the latch.
14. Remove the interior lock rod from the interior handle.
15. Remove the interior handle lock rod and grommet from the carrier.
16. Disconnect the latch electrical connector.
17. Turn the carrier plate over and slide the latch bracket assembly to remove from the carrier plate slots (1).
18. Remove the push pin (1) from the handle. 19. Remove the spring (3) and handle (2) from the carrier.
20. Disconnect the speaker electrical connector.
21. Remove the speaker bolts and speaker from the carrier.
22.   Remove the electrical harness (1) from the carrier plate.
23.   Release harness from all the hooks in the carrier plate.
24.   Disconnect the connector (2) from the motor.
25.   Remove the electrical harness (3) from the carrier plate.
26.   Remove the harness from the carrier plate.
27. Remove the screws and window motor from the carrier plate.
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CARRIER PLATE - REAR DOOR📷 18
1. Install the motor and screws to the carrier plate and tighten to 3.5 N.m (31 in. lbs.).
2.   Install the harness to the carrier plate.
3.   Install the electrical harness (3) and seat the rubber grommet into the carrier plate.
4.   Connect the electrical connector (2) to the motor.
5.   Route the harness through all of the hooks in the carrier plate.
6.   Install the electrical harness (1) and seat the rubber grommet into the carrier plate.
7. Install the speaker and bolts to the carrier and tighten to 1.5 N.m (13 in. lbs.).
8. Connect the speaker electrical connector. 9. Install speaker wire to wire clip.
NOTE: Make sure that the push pin is seated flush with the carrier.
10. Install the handle (2) and spring (3) to the carrier. 11. Install the push pin (1) into the carrier, spring and the handle.
12. Install the latch bracket assembly to the carrier plate slots (1) then slide the latch bracket until fully seated.
13. Connect the latch electrical connector.
14. Install the interior handle lock rod into the carrier and seat the grommet.
NOTE: All the lock rods are color coded to help identify the location for the particular lock rod.
15. Install the interior lock rod to the interior handle (2). Make sure the lock rod is positioned properly to the carrier (1).
16. Connect the interior handle lock rod to the latch.
17. Install the inside lock rod (1) to the carrier plate (3) and seat the grommet (2).
18. Connect the inside lock rod to the latch.
19. Install the carrier plate (2) to the door (4). 20. Install the electrical connector (1) to the door (4) and connect the electrical connector.
21. Install the screws securing the door latch to the door shut face and tighten screws to 7 N.m (60 in. lbs.). 22. Install the 9 screws to the carrier plate and tighten screws to 5.5 N.m (50 in. lbs.).
23. Connect the door harness electrical connector (1) to the body connector (2) at the B-pillar.
24. Install the rear nut (1) to the exterior handle and tighten to 4.5 N.m (40 in. lbs.). 25. Install the door plug (2) to the door.
NOTE: Place the glass in the full down position in order to access the window regulator.
26. Access the window regulator through the hole in the carrier plate. Connect the door glass (1) to the window regulator (2). 27. Apply the adhesive tape to the inspection hole of the carrier plate.
28. Install the trim panel to the door, see INSTALLATION. 29. Connect the negative battery cable to the battery.
NOTE: Cycle the door lock, open with interior and exterior door handles and operate the power window to make sure everything is working properly and binding exists.
DOOR - REAR
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DOOR - REAR📷 3
1. Loosen the battery terminal nut and use a battery terminal removal tool (2) to disconnect the negative battery cable from the battery (1).
2. Disconnect the door harness electrical connector (1) from the body connector (2) at the B-pillar.
NOTE: Use a grease pencil or equivalent, mark the location of the upper (1) and lower (3) hinges on the door (2) for alignment during installation.
3. Support the rear door with a suitable lifting device. 4. Remove the nuts (4) attaching the door (2) to the upper (1) and lower (3) hinges. 5. Carefully remove the door (2) from the vehicle.
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DOOR - REAR📷 2
1. Carefully position the door (2) to the upper (1) and lower (3) hinges using a suitable lifting device.
2. Loosely install the nuts (4) to the door studs and hinges at the B-pillar. 3. Align the door to the body using the reference marks made during the removal procedure. 4. Tighten the hinge to door nuts to 36.5 N.m (27 ft. lbs.).
5. Connect the door harness electrical connector (1) to the body connector (2) at the B-pillar. 6. Connect the negative battery cable. 7. Adjust the door as necessary. See SPECIFICATIONS.
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DOOR - REAR📷 1
NOTE: It is recommended that you adjust the rear door before adjusting the front door.
Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels. During adjustment procedures, it is recommended that all the hinge fasteners be loosened except for the upper most fasteners. Adjustments can be made using the upper fasteners to hold the door with final torque of the fasteners occurring after correct door positioning is achieved.
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FORE/AFT📷 1
NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge pillar fasteners one hinge at a time and moving the door to the correct position.
1. Support the door with a suitable lifting device. 2. Loosen the hinge to hinge pillar fasteners. See REMOVAL.
3. Adjust the door to the correct position. See SPECIFICATIONS. 4. Tighten the hinge pillar fasteners to 26 N.m (19 ft. lbs.). See INSTALLATION.
NOTE: Use a suitable body sealer on the hinge to body mating surfaces.
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UP/DOWN
NOTE: Up/down door adjustment is done by loosening either the hinge to the hinge pillar fasteners or the hinge to door fasteners and moving the door to the correct position.
NOTE: When the up/down adjustments are done correctly, the top of the door is positioned over flush to the roof. See SPECIFICATIONS.
1. Support the door with a suitable lifting device. 2. Remove the latch striker. See REMOVAL. 3. Loosen the hinge to hinge pillar fasteners (see REMOVAL) or loosen the hinge to door fasteners (see
REMOVAL).
4. Adjust the door to the correct position. See SPECIFICATIONS. 5. Tighten the hinge pillar fasteners to 26 N.m (19 ft. lbs.) or the door to hinges fasteners to 36.5 N.m (27 ft. lbs.). See INSTALLATION. 6. Install the latch striker. See INSTALLATION.
IN/OUT
NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one hinge at a time and moving the door to the correct position.
  1.   Support the door with a suitable lifting device.
  2.   Remove the latch striker. See REMOVAL.
  3.   Loosen the hinge to door fasteners. See REMOVAL.
  4.   Adjust the front of the door to the correct position. See SPECIFICATIONS.
  5.   Tighten the door to hinges fasteners to 36.5 N.m (27 ft. lbs.).
  6.   Install the latch striker. See INSTALLATION.
APPLIQUE - REAR DOOR