GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Upper Hinge and Lower Hinge Replacement

Removal Procedure
  1. Open the front door.
  2. Disconnect the front door rubber conduit from the front door pillar.
  3. Disconnect the front door electrical connector at the front door pillar.
  4. Remove the front door check link bolt.

    5. Object Number: 595413 Size: SH
  5. Remove the front door hinge intermediate bolts.
  6. Remove the front door from the vehicle with an assistant.

    7. Object Number: 736499 Size: SH
  7. Clean the area around the hinges and mark the location with a grease pencil.
  8. Remove the front door hinge bolts (2).

    9. Object Number: 737650 Size: SH
  9. Remove the front door hinge pillar bolts.
  10. Remove the front door hinge.

Installation Procedure

    Object Number: 737650 Size: SH
  1. Position the front door hinge to the alignment marks on the hinge pillar.

    2. 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.

  2. Install the front door hinge pillar bolts.

    3. Tighten
    Tighten the bolts to 28 N·m (21 lb ft).


    Object Number: 736499 Size: SH
  3. Position the front door hinge to the alignment marks on the front door.
  4. Install the front door hinge bolts (2).

    5. Tighten
    Tighten the bolts to 28 N·m (21 lb ft).

  5. Position the door to the vehicle with an assistant.

    6. Object Number: 595413 Size: SH
  6. Install the front door hinge intermediate bolts (1).

    7. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  7. Install the front door check link bolt.

    8. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  8. Connect the front door electrical connector at the front door pillar.
  9. Connect the front door rubber conduit to the front door pillar.
  10. Close the front door.