Trim door hardware carrier and methods of assembling vehicle door

A method of assembling a motor vehicle door including a structural door body comprising inner and outer sheet metal layers joined together at their peripheries to define a cavity therebetween, wherein the inner sheet metal layer includes at least one relatively large opening providing access to the cavity, the method including:

• provisioning a door module assembly comprising:
• a carrier holding a plurality of door hardware components in a pre-configured orientation, including at least one window regulator rail;
• a lower trim panel, connected to the carrier;
• and
• an upper trim panel, articulated to the lower trim panel, and moveable between a position generally distanced from the carrier and an installed position generally flush with the lower trim panel and overlapping the carrier;
• hanging the at least one rail on the inner sheet metal layer, thereby suspending
• the door module from the structural door body;
• fastening the at least one rail to the inner sheet metal layer;
• installing various hardware components to the structural door body;
• and
• moving the upper trim panel into the installed position, wherein the upper and lower trim panels cover substantially the entire surface area inner sheet metal layer.

A door module assembly for a motor vehicle door, wherein the door includes a structural door body having inner and outer sheet metal layers which define a cavity therebetween and the inner sheet metal layer includes at least one access opening to the cavity, the door module assembly comprising:

• a carrier plate having a plurality of door hardware mounted thereon, the carrier plate being formed from a substantially water-impervious material and sized to cover and seal the at least one access opening when the carrier plate is mounted against the inner sheet metal layer;
• a first trim panel pre-assembled to the carrier plate prior to installation of the door module to the structural door body;
• and
• at least a second trim panel, pre joined to the first trim panel prior to installation of the door module to the structural door body, the second trim panel being moveable between a non-installed position which is distanced from the carrier plate and an installed position generally flush with the first trim panel and overlapping the carrier plate.