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

Removal Procedure

    Object Number: 590994 Size: SH
  1. Disconnect the front door wiring harness (1) from the main body wiring harness at the front door pillar.
  2. Pull the wiring harness (1) out through the opening in the body pillar.

    3. Object Number: 737652 Size: SH
  3. Remove the front door check link bolt.
  4. Remove the front door hinge intermediate bolts.
  5. With the aid of an assistant, remove the front door.

    6. Important: Perform the following procedures in order to disassemble the door following removal.

  6. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
  7. Remove the locking system module. Refer to Front Side Door Locking System Module Replacement .
  8. Remove the mirror. Refer to Outside Rearview Mirror Replacement .
  9. Remove the outside handle. Refer to Outside Handle and Lock Cylinder Replacement .
  10. Remove the door hinges. Refer to Front Side Door Hinge Replacement .
  11. Remove the door check link. Refer to Front Side Door Check Link Replacement .
  12. Remove the window run channel. Refer to Window Channel Replacement .
  13. Remove the auxiliary sealing strip. Refer to Front Side Door Auxiliary Sealing Strip Replacement .
  14. Remove the carpet retainer. Refer to Carpet Retainer Replacement in Interior Trim.
  15. Remove the rubber conduit from the front door body pillar.

Installation Procedure

    Important: Perform the following procedure in order to assemble the door before installation.

  1. Connect the rubber conduit to the front door body pillar.
  2. Install the carpet retainer. Refer to Carpet Retainer Replacement in Interior trim.
  3. Install the front door auxiliary sealing strip. Refer to Front Side Door Auxiliary Sealing Strip Replacement .
  4. Install the window run channel. Refer to Window Channel Replacement .
  5. Install the door check link. Refer to Front Side Door Check Link Replacement .
  6. Install the door hinges. Refer to Front Side Door Hinge Replacement .
  7. Install the outside handle. Refer to Outside Handle and Lock Cylinder Replacement .
  8. Install the mirror. Refer to Outside Rearview Mirror Replacement .
  9. Install the locking system module. Refer to Front Side Door Locking System Module Replacement .
  10. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .

    11. Object Number: 737652 Size: SH
  11. To install the door with the aid of an assistant, position the front door to the door hinges.

    12. 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.

  12. Install the front door hinge intermediate bolts.

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

  13. Install the front door check link bolt.

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


    Object Number: 590994 Size: SH
  14. Route the wiring harness (1) through the opening in the front door body pillar.
  15. Connect the wiring harness (1) to the main body harness at the front door body pillar.