How do you replace the drivers side door on a 1998 Malibu?

Answer 1

I am currently doing a completetear down on a 98 Malibu so I think I can help. All

info is offered with out guarantee.

A) Removal

1) Safety First First disconnect the battery.

2) Remove the Door Panel. Remove the mirror trim plate. It just pops off. Remove the door handle surround with I think a T-10 or T-15 screwdriver. Be sure to disconnect the power lock switch connector. There are also two 7mm bolts behind the armrest handle covered by a trim plate. The trim plate pops off with any small pry tool or some times your fingers if you have good dexterity. Remove the 7mm bolts. Then carefully pry the panel from the door. It is held in place by clips. The clips can be released by

carefully prying with a huge flat blade screwdriver or using a panel removal tool.

After the clips are disengaged tilt the panel up and away from the door while

lifting. be careful of the wires going to the window controls and power locks. Once

you have enough room disconnect switch assemblies on the door panel. Place the door panel somewhere safe.

3) Remove Vapor Barrier

4) Remove the wiring Harness

Carefully disconnect all connections in the door. These are mainly to the

mirror, speaker, window motor, and (2) connectors to the door latch assembly. If I

have missed anything electrical connections please carefully disconnect them now.

There will be various plastic clips on the door wiring harness that hold it in place.

You will need to release these clips by carefully compressing the plastic taps with

needle nose pliers while pulling. Once the harness has been rendered free it is time

to remove it from the door. Using a large flat blade screwdriver press gently on the

flexible rubber conduit going in to the front edge of the door. You should press from

the side compressing its shape. You are trying to unseat it from the grommet edge with out tearing it so be careful. Once it can be worked free of the edge do so. Now

remove the harness by working it out the hole that the flexible conduit was seated

in. All wiring from the chassis should now be free from the door.

WARNING:::: The next steps vary based on your source of replacement door.

This walk through assumes you are using a empty replacement door.

If you are using a complete door from a recycling yard then follow steps 1-4,and 7

for old door and replacement door, then follow steps 10-16,18, and 23-31.

5) Remove the Mirror by detaching the three 10mm nuts then carefully pry loose.

6) Remove the Window and regulator Assembly Plate. Remove connecting rod to interior door handle by detaching clip. Leave the other connection in place for now. Remove bolts holding window track / guides in place. Remove all retaining bolts and screw holding the regulator assembly plate to door frame. carefully work assembly plate free and lower it down enough to access the window nuts. Loosen the window nuts and detach the window from the regulator. Carefully push the window upward back in to it's normal position. Move you regulator plate assembly mostly free of the door. Now detach the other rod going to the interior door handle. You regulator plate assembly should be free. set it some place safe. Now carefully lower the window back in to the door. You want to get it off the tracks / guides. Remove the window weather stripping by starting at the front lower corner and pulling it free. Once you have the window mostly in the door you should be to slightly turn it and raise it out of the door using the curve to your advantage. carefully wrap and protect the window placing it some place extra safe.

7)Remove the exterior door handle and Lock cylinder. swing the rod clip on the lock cylinder control arm to disengage the lock control rod. Follow the exterior handle control rod down to the latch mechanism and separate the white clip holding it to the latch mechanism actuation lever. Now be careful as this clip only opens one way and the side that opens is closest to the exterior door panel. Once the clip is open pop the control rod sideways toward the open face of the clip to free it. Now remove the 2 t-30 bolts holding the exterior handle and lock cylinder to the door and remove toward the exterior.

8) Remove the three t-30 bolts holding the latch mechanism to the door and remove.

9) Remove trim if needed to match replacement door.

10) Remove door There are a few ways to separate the hinges on a 98 Malibu. The easiest I have found when replacing a door is to remove the single bolt on each hinge that allow you to separate the hinge and raise the door free. Be careful the door can be heavier then you think.

11) Remove hinge If needed remove hinge parts from removed door.

12) Recycle the old door.

B) Installation

13) If needed paint replacement door to match.

14) Install hinge parts if needed.

15) place door on hinges aligning top and bottom pins. Then install a hinge bolt in

each hinge.

16) install trim if needed.

17) Install door latch mechanism.

18) install The exterior door handle with lock cylinder to match your key. reconnect

the rods as they had been.

19) Carefully work the window back into the door.

20) Install the window Weatherstripping / channelling. Slide the window up in to it

place.

21) Attach the bend ended control rod that goes to the interior door handle on the

regulator mechanism plate. Work the regulator mechanism plate mostly back into place. When close slide the window down by hand and attach to the regulator mechanism using the two nuts. Carefully work the mechanism and window up in to place. Then attach mechanism to the door. Connect the plastic clipped connector for the other Interior door handle control rod. Anchor the lower end of the window channel to the door.

22) Install the mirror.

23) Reinstall harness to door. Work the Harness carefully back into the door. Once the harness is completely back inside the door, Re-seat rubber conduit on grommet edge. Now attach all the clips that hold the harness in place. Connect harness to Latch mechanism, window motor, speaker, and mirror.

24) Install vapor barrier.

25) Reinstall door Panel. Set the door panel carefully in the window opening edge and start to lower it to place. When close enough reconnect the window control panel wiring. Make sure that the lock panel wiring is accessible through the opening for the interior door handle.

26) attach the wiring for the lock switch on the interior door handle trim plate.

27) Reconnect Battery.

28) test all switches and mechanics.

29) If some thing does not function check you work, and fix the problem. Before

continuing to number 30.

30) Press panel into place seating it securely. Install 2 10mm bolts behind armrest

handle. Install cover plate. Work Interior Door Latch trim plate back into place and

install with proper screw. Install interior mirror trim plate.

31) enjoy your success.

RevT 09'