Rear Door Replacement. Pontiac Sun Runner - 4WD (Canada) 1998

For 1990-2009 cars

## Rear Door Replacement 2 Door

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the spare tire from the vehicle. Refer to Spare Tire Replacement in Tires and Wheels.
3. Open the rear door.
4. Remove the rear door water deflector. Refer to Water Deflector Replacement .
5. Disconnect the following electrical connectors:

• | The license plate lamp

• | The center high-mounted stoplamp

6. Feed the wiring harness through the rear door (2).
7. Remove the grommet and wiring harness from the rear door (2).
8. Place a piece of wood between a floor jack and the rear door (1) in order to support the door.
9. Remove the 4 bolts which secure the lower hinge (2) to the rear door (1).
10. Remove the 2 bolts which secure the upper hinge (2) to the rear door (1).
11. Remove the rear door (1) from the vehicle.

### 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 (1) to the vehicle. Secure the rear door to the upper hinge (2) with the 2 bolts.

Tighten
Tighten the rear door to hinge bolts to 34 N·m (25 lb ft).

2. Secure the rear door to the lower hinge (2) with the 4 bolts.

Tighten
Tighten the rear door to lower hinge bolts to 34 N·m (25 lb ft).

3. Install the rear door open stop pin (3) to the rear door open stop (1).
4. Install the rear door support (2) to the rear door (1). Secure the support with 1 nut.

Tighten
Tighten the rear door support nuts to 15 N·m (11 lb ft).

5. Feed the wiring harness through the rear door.
6. Install the grommet.
7. Connect the following electrical connectors:

• | The license plate lamp

• | The center high-mounted stoplamp

8. Install the rear door trim panel. Refer to Rear Door Trim Panel Replacement .
9. Close the rear door (2).
10. Install the spare tire to the vehicle. Refer to Spare Tire Replacement in Tires and Wheels.
11. Connect the negative battery cable.

## Rear Door Replacement 4 Door

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the spare tire from the vehicle. Refer to Spare Tire Replacement in Tires and Wheels.
3. Open the rear door.
4. Remove the rear door water deflector. Refer to Water Deflector Replacement .
5. Disconnect the rear defogger electrical connector.
6. Disconnect the rear wiper motor electrical connector, if equipped.
7. Disconnect the following electrical connectors:

• | The license plate lamp

• | The center high-mounted stoplamp

8. Feed the wiring harness through the rear door (2).
9. Remove the grommet and wiring harness from the rear door (2).
10. Remove the nut which secures the rear door support (2) to the rear door opening.
11. Place a piece of wood between a floor jack and the rear door (1) in order to support the door.
12. Remove the 4 bolts which secure the lower hinge (2) to the rear door (1).
13. Remove the 2 bolts which secure the upper hinge (2) to the rear door (1).
14. Remove the rear door (1) from the vehicle.

### 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 (1) to the vehicle. Secure the rear door to the upper hinge (2) with the 2 bolts.

Tighten
Tighten the rear door to hinge bolts to 34 N·m (25 lb ft).

2. Secure the rear door to the lower hinge (2) with the 4 bolts.

Tighten
Tighten the rear door to lower hinge bolts to 34 N·m (25 lb ft).

3. Install the rear door open stop pin (3) to the rear door open stop (1).
4. Install the rear door support (2) to the rear door (1). Secure the support with 1 nut.

Tighten
Tighten the rear door support nuts to 15 N·m (11 lb ft).

5. Feed the wiring harness through the rear door.
6. Install the grommet.
7. Connect the following electrical connectors:

• | The license plate lamp

• | The center high-mounted stoplamp

8. Connect the rear wiper motor electrical connector.
9. Connect the rear defogger electrical connector.
10. Install the rear door trim panel. Refer to Rear Door Trim Panel Replacement .
11. Close the rear door (2).
12. Install the spare tire to the vehicle. Refer to Spare Tire Replacement in Tires and Wheels.
13. Connect the negative battery cable.