There is no need to use a larger grille, except cosmetics, and IMO, the '91-'92 grille doesn't look like it was properly designed in. The 4" grille won't block ANY sound from the larger speaker.
You would need to be able to cut metal, and make a new back plane. You would need to replicate all 3 mounting locations, or else there WILL be a sound difference -- the grille buzzing with the speaker vibration. You'll also need to ensure that the backplane is solidly connected to the door panel for the same reason. You'd also need to make it all complete, to keep the door panel from buzzing at the lower edge.
There MIGHT be a slight difference in sound around the area that your ankles and knees reside, at very high (>12kHz) frequencies if it's a coax speaker and the tweeter is recessed enough that the structure blocks line of sight.
I wouldn't mod the door panel, but it's possible to do.