GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Malibu 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Replacement

Removal Procedure
  1. Remove the rubber conduit from the door, if equipped.
  2. Remove the carpet retainer. Refer to Carpet Retainer Replacement .

    3. Object Number: 590994 Size: SH
  3. Pull the carpeting back enough to expose the door wire harness, if equipped.
  4. Disconnect the door wire harness connectors, if equipped.
  5. Pull the harness through the conduit access hole in order to remove the harness from the vehicle.
  6. Remove the door check link to hinge pillar bolt.
  7. Support the door.

    8. Object Number: 591012 Size: SH
  8. Mark the position of the door hinge relative to the door.
  9. Remove the lower hinge nuts (1) from the door.
  10. Remove the upper hinge nuts (2) from the door.
  11. Remove the door from the hinges.

Installation Procedure

    Object Number: 591012 Size: SH
  1. Install the door to the hinges.
  2. Snug the upper hinge nuts (2) in order for the door to move.
  3. Snug the lower hinge nuts (1) in order for the door to move.
  4. Carefully close the door.
  5. Ensure that the door alignment is correct.
  6. Open the door slowly.

    7. 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.

  7. Tighten the upper hinge nuts (2) to the hinge pillar.

    8. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

  8. Install the lower hinge nuts (1) to the hinge pillar.

    9. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

  9. Inspect the door for proper alignment.
  10. Install the door check link to hinge pillar bolt.

    11. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 590994 Size: SH
  11. Feed the wire harness through the conduit access hole, if equipped.
  12. Install the rubber conduit to the door and body, if equipped.
  13. Connect the door wire harness, if equipped.
  14. Push the carpeting back into position.
  15. Install the carpet retainer. Refer to Carpet Retainer Replacement .