GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Body and Accessories 🢒 Doors 🢒 Door Replacement

Removal Procedure

    Object Number: 276402 Size: SH
  1. Remove the rubber conduit from the door, if equipped.
  2. Disconnect the wire harness from the door through the conduit access hole, if equipped.
  3. Remove the door hold open bolt.
  4. Support the door.
  5. Mark the position of the door hinge (4) relative to the hinge pillar.
  6. Remove the lower hinge bolts (3) from the hinge pillar.
  7. Remove the upper hinge bolts (2) from the hinge pillar.
  8. Remove the door (1) from the body.

Installation Procedure

    Notice: Door hinge parts could cause damage to other door components if not replaced with the same part or equivalent. Do not use replacement parts of lesser quality or substitute design. Specified torque values must be used during assembly in order to ensure proper retention.

  1. Install the door (1) to the body.
  2. Snug the upper hinge bolt (2) in order for the door to move.
  3. Snug the lower hinge bolt (3) in order for the door to move.
  4. Carefully close the door (1).
  5. Adjust the door for proper alignment.
  6. Open the door (1) 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. Install the upper hinge bolt to the hinge pillar.

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

  8. Install the lower hinge bolt (3) to the hinge pillar.

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

  9. Inspect the door (1) for proper alignment.
  10. Install the door hold open bolt to the hinge pillar bolt.

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

  11. Feed the wire harness through the conduit access hole, if equipped.

    12. Object Number: 276402 Size: SH
  12. Install the rubber conduit to the door (1), if equipped.
  13. Connect the door wire harness, if equipped.
  14. Install the door water deflector. Refer to Door Water Deflector Replacement .

    15. Object Number: 276401 Size: SH
  15. Install the door trim panel (1). Refer to Door Trim Panel Replacement .