GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Monte Carlo 🢒 Body and Accessories 🢒 Doors 🢒 Rear Door Replacement

Removal Procedure
  1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .
  2. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  3. Remove the rear door outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing Strip Replacement .
  4. Remove the rear door window. Refer to Rear Side Door Window Replacement .
  5. Remove the rear door frame applique. Refer to Rear Door Frame Applique Replacement .
  6. Remove the rear door window regulator. Refer to Rear Side Door Window Replacement .
  7. Remove the rear door outside door handle. Refer to Rear Side Door Outside Handle Replacement .
  8. Remove the rear door inside door handle. Refer to Rear Side Door Inside Handle Replacement .
  9. Remove the rear door lock. Refer to Rear Door Lock Replacement .
  10. Remove the rear door window channel. Refer to Rear Side Door Window Weatherstrip Replacement .
  11. Remove the rear door rubber conduit. Refer to Rear Side Door Conduit Replacement .
  12. Remove the rear door wiring harness. Refer to Rear Side Door Wiring Harness Replacement .
  13. Remove the rear door body side moldings. Refer to Body Side Molding Replacement in Exterior Trim.
  14. Support the rear door.
  15. Remove the rear door hinge. Refer to Rear Side Door Hinge Replacement .
  16. Remove the rear door from the vehicle with an assistant.

Installation Procedure

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the rear door hinge. Refer to Rear Side Door Hinge Replacement .

    2. Tighten
    Tighten the rear door hinge bolts to 33 N·m (24 lb ft).

  2. Install the rear door wiring harness. Refer to Rear Side Door Wiring Harness Replacement .
  3. Install the rear door rubber conduit. Refer to Rear Side Door Conduit Replacement .
  4. Install the rear door body side moldings. Refer to Body Side Molding Replacement in Exterior Trim.
  5. Install the rear door window channel. Refer to Rear Side Door Window Weatherstrip Replacement .
  6. Install the rear door lock. Refer to Rear Door Lock Replacement .
  7. Install the rear door inside door handle. Refer to Rear Side Door Inside Handle Replacement .
  8. Install the rear door outside door handle. Refer to Rear Side Door Outside Handle Replacement .
  9. Install the rear door window regulator. Refer to Rear Side Door Window Replacement .
  10. Install the rear door window. Refer to Rear Side Door Window Replacement .
  11. Install the rear door outer belt sealing strip. Refer to Rear Door Window Belt Outer Sealing Strip Replacement .
  12. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  13. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .
  14. Inspect the rear door for proper operation and alignment. Refer to Rear Door Adjustment .