How did you remove the front speaker cover?

Armrest Door Pull
Remove Rubber Cover
Remove 10mm ***** The first step is to pry out the plastic trim plate behind the chrome colored door release handle using a small flathead screwdriver.Then remove the 10mm ***** behind the plate using a ratcheting wrench with an extension bar attached.
Next pry out the rubber cover at the bottom of the door pull located in the center of the arm rest. Use a Torx T-25 (star bit) screwdriver to remove the two screws.
Remove Torx T25 Screws
2 T-25 Torx & 1 10mm *****
Pry Up Arm Rest Panel Use a flathead screwdriver to pry up the rear of the plastic arm rest panel. There is a plastic hook at the front of the panel, so only pry it up from the rear edge.
Lift Rear End First
Plastic Hook At Front of Panel
Power Window Connector After you lift out the arm rest panel, you'll need to disconnect the power connector for the window and door lock switches.
Push Connector Release Tab
Power Connector Unplugged
Two More T25 Screws Push on the release tab with a flathead screwdriver and pull out the power window / door lock connector.Use a Torx T25 screwdriver to remove the two screws located below the arm rest panel.
Remove T25 Torx Screws
Outer Edge of Panel
Push In Center of Fastener Then move to the outer edge of the door panel and locate the two small round fasteners. Use a small screwdriver to pop in the center pins of the two fasteners.
Pull Out Plastic Rivet
Black Plastic Fastener Removed
Remove Lower Fastener Pull out the two plastic rivet fasteners and set them aside in a safe place.
Pull Panel Away From Door
White Plastic Pop Rivets
Pull Off Sail Panel Grab the door pull in the arm rest and tug it towards yourself to disengage the pop rivet friction fasteners that hold the panel to the door frame.Move to the top corner of the door panel and pry off the triangular "sail" panel. On some vehicles, the sail panel contains the tweeter speaker.
Lift Panel Off Door Lock
Pull Out Door Pull Cable Lift the door panel off the door lock button and tilt the top of it out towards yourself.Use a pair of needle nose pliers to gently lift the metal ball at the end of the door opener cable out of the mechanism.
Disconnect the door cable from the back side of the door panel.
Door Pull Cable Removed
Disconnect Power Mirror Then disconnect the power connector for the side view mirror by lifting up on the release tab. Slide the power connector off the plastic anchor on the metal door frame.
Slide Connector Off Anchor
Unlock Connector
Connector Detached Look behind the door panel and locate the large wire connector with the pink lever lock. Swing the lever open to unlock the connector and separate it from the socket.


Door Panel Removed
Power Window Motor
10mm Bolts Now the door panel can be completely removed by lifting it up and off the door frame.To replace the power window motor, remove the 10mm bolts.
Stock OEM Door Speaker
Remove 7mm ***** The stock "OEM" speaker is held in place by a single 7 mm *****. Remove it with a socket and ratcheting wrench.
Pry Off OEM Speaker
Speaker Removed
Disconnect Power Plug If the speaker is stuck to the door frame, gently pry it off with a small flathead screwdriver.Disconnect the speaker's power plug by pressing the release tab with the small flathead screwdriver.
Fits 5.25", 6.5", 6.75"
Re-installing Door Panel According to the Crutchfield website, the 2008 to 2012 Chevrolet Malibu's front door speakers can be replaced withaftermarket speakers in the following sizes: 5 1/4", 6 1/2" or 6 3/4" speakers with the use of a bracket.If you'd like to reduce road noise, make your car quieter and also improve the sound from your speakers, I'd recommend applying some Dynamat Sound Deadener on to the metal door frame.
Re-Attach To Anchor
Plug In Power Side View Mirror
Re-Insert Power Connector To re-install the door panel, first hold the panel close to the door frame before re-connecting the large wire plug. Swing the pink lever closed to lock it in place.Slide the socket for the power side view mirror back on to its anchor and insert the power plug.
Lock Power Connector
Pink Lever Locked
Re-Insert Door Pull Cable Ball Insert the metal ball at the end of the door opener cable back in to the door handle mechanism.Slide the black plastic cone part of the cable back into the slot in the door opener assembly.
Door Opener Cable Reinstalled
Hang Door Panel On Frame Gently lower the door panel down on to the edge of the door frame with the door lock switch through the opening at the top.
Line Up White Plastic Fasteners
Push On Sail Panel
Push Door Panel In Place Move to the bottom of the door panel and line up the white plastic pop rivet fasteners with the holes in the metal door frame.Push all around the door panel to re-insert the pop rivet fasteners.
Re-attach the sail panel at the top corner of the door frame.
Push Panel Flush Against Frame
Insert Side Edge Fasteners
Insert Larger Piece First Next move to the side edge of the door panel and first re-insert the larger piece of the two fasteners. Then insert the smaller "pin" piece of the fastener into the middle of the larger piece.
Insert Small "Pin" Piece
Install Lower Edge Fastener
Tighten 2 T25 Torx Screws
Re-Attach Power Connector
Insert Front Hook First Insert and tighten the two Torx T-25 screws located under the arm rest.Re-attach the power connector to the plastic arm rest panel.
First insert the hook at the front of the arm rest panel and then snap the rear end in place.
Pop Arm Rest Panel In Place
Tighten 2 T25 Screws
Replace Rubber Cover Insert and tighten the two T25 Torx screws into the door pull cup. Then replace the rubber cover over the two screws.
Tighten 10mm Door Handle *****
Replace Door Handle Trim Plate
Malibu Door Panel Replaced Replace the 10mm ***** that goes above and behind the door opener handle and tighten it. Pop in the plastic trim plate behind the door handle.

I presume the back cover does not really open from the back or if it does you cannot see the speakers from the rear?

which if you cannot see them with rear cover removed leaves two possible paths, the entire panel unit with the screen has to be removed and they are under it OR the entire front may be snapped together and has to be pryed out (if you see a seam or crack like area running around the side up front get a thin metal putty knife and try to open it, seen a lot of computer LCD monitors where they come apart from the front--and are snapped together much like some of our plastic remotes--have to go in from the front and not the rear.

Do some careful looking to see what you have.

The lower front speaker grille will need to be removed first by removing the screws along the back edge of the rear cover as shown in the pic below. then just pop the lower speaker grille off then you will see the screws along the bottom edge of the front control panel and also on the rear edge again then that panel lifts off but you will need to reach behind as your removing it to unplug the wires that are hooked to both small circuit boards on that panel ( keyboard & aux input boards)

Section 01-09: Mirrors, Rear View 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Mirror, Power-Outside Rear View Removal

1. Disconnect battery ground cable (14301).
   

1. Remove front door trim panel (23942). Refer to Section 01-05.
   

1. Remove radio speaker grille from cover assembly by squeezing or pinching between thumb and index finger.
   

1. Remove two screws from cover assembly.
   

1. Disconnect outside rearview mirror wiring connector (C515-LH; C615-RH). Remove wiring guides as necessary.
   

1. Remove three outside rear view mirror retaining nuts. Remove outside rear view mirror (17682) while guiding wiring and connector through hole in door.
   

Item Part Number Description 1 17682 Outside Rear View Mirror 2 N621906-S36 Nut (3 Req'd) 3 F8DB-17D699-
AAW Cover Assembly Rear Substrate-LH 3 F8DB-17D698-
AAW Cover Assembly Rear Substrate-RH 4 N808968 Screw 5 F8DB-18B984-
AAW Speaker Grille-Standard (No Badge)-LH 5 F8DB-18985-
AAW Speaker Grille-Standard (No Badge)-RH 5 F8DB-18K901-
BAW Speaker Grille-Mach-LH 5 F8DB-18978-
BAW Speaker Grille-Mach-RH 5 F8DB-238A35-
AAW Speaker Grille-Blank (No Speaker)-LH 5 F8DB-238A34-
AAW Speaker Grille-Blank (No Speaker)-RH A - Tighten to 6-8 Nm (54-70 lb-in) ------------------
Trim Panel, Door Front
Removal

1. Remove cover behind inside door handle.
   

1. Remove screw from bottom of pull cup retaining front door trim panel to front door (20124).
   

1. Remove three screws retaining front door trim panel to front door.
   

1. NOTE: Do not attempt to remove more than one pushpin at a time.
   
   Using Rotunda Windshield and Molding Trim Removal Kit 107-R0401 or equivalent, remove the door trim panel by pulling one door trim panel pushpin at a time from the inner door skin.
   

1. Disconnect electrical connectors as necessary. Refer to Section 01-14A.
   

Installation

1. Follow removal procedure in reverse order.
   

1. Replace all pushpins with new pushpins (N808994-S).
   

Front Door Trim Panel

My AU11 is a XR8 with premium sound. I say this because maybe the speakers in the doors change the way the door panel is removed. I am describing the front door panel removal.

1. Remove the door lock knob by pulling it up.
2. Remove the two screw covers covering the screws which are above the speakers by gently prizing them out with a screwdriver.
3. Under one of the covers (the one closest to the speaker) is a 10mm bolt, remove this bolt by using a small 10mm socket.
4. Remove the two screw covers on the bottom of the door and remove the two phillips screws underneath.
5. Remove the phillips screw that is near the door lock knob but on the centre pillar side of the door panel. This screw is the only one that is not under a removable cover.
6. Remove the door release bezel by gently prizing the top of the bezel between the vinyl and the bezel with a screwdriver. For this you need to be gentle in order not to damage the vinyl.
7. Once the bezel is off you can see another 10mm bolt underneath that must be removed.
8. Gently prize up the electric window switches. I prized mine up carefully by using a screwdriver in the gap between the armrest and the electric switch panel. Unplug the electric switch panel which is a captive plug so you need to use a screwdriver to release the catch. You can also do the same for the electric mirror plug once the door panel is off.
9. Under the electric switch panel is another phillips screw that must be removed.
10. The door panel can now be removed by gently prizing it away from the door. I just used my hands for this but maybe you will need a wooden spatula or similar to assist. The door panel will offer some resistance and pop once the clips release. If you encounter strong resistance maybe you have another clip or screw etc that needs to be located.

Dont forget to unplug the electric mirror wires.

Replacement of Front and Rear Door Speakers

Required Tools:

#2 Phillips Screwdriver (magnetic tip is useful)
9 mm Nut Driver
8” or 10” Flat Tip Screwdriver
Small awl or other sharp pointed instrument
Soldering Iron w/solder or 8 to 10 small wire **** splices
8 to 10 small machine screws -- #8 x ¾” or equivalent 8 to 10 small machine screw nuts & flat washers to match
Thread locking compound “Loctite” (optional)
6” wooden dowel of ½” diameter to be used as a drift
Small mallet or hammer

1) Whenever you are attempting to a remove door panel to gain access to the speaker, or any other electrical component, absolutely disconnect the negative battery cable. Battery power is supplied to each door window motor and it’s always prudent to de-energize these circuits before you attempt any panel work.

2) XJ40 door inner panels (front or rear) are comprised of an upper and lower section, which interface to provide complete inner door coverage. Neither panel is difficult to remove nor are any specialized tools required.


3) Remove the Upper Inner Door Panels as follows:

It’s a good idea to store all the removed parts and screws in the adjacent foot well for safekeeping and easy access when you are putting everything back together.

a) Using a small awl (or equivalent), remove the small “square” plastic cover for the inner door lock release mechanism (upper right side when facing inner side of door). It pivots towards the front of the car.

b) Using the #2 Phillips screwdriver, remove the inner door lock release mechanism plastic / chrome escutcheon. It’s held in place by a single machine screw. Pull out on the door lock release mechanism and the escutcheon is easily removed.

c) Using both hands, pull out on the wood veneer panel at the inner door lock release mechanism to provide clearance and slide the panel towards the front of the car. The panel is secured on the left side by slip-in clips and they release easily.

d) Using the #2 Phillips screwdriver, remove the two sheet metal screws on the left side. For the front doors only, lift the bottom of the rubber ventilation boot at the front edge of the door and remove the sheet metal screw. Additionally, for the front door only, use the large flat screwdriver as a lever to ease out the single “fir tree” type press-fit connector. Neither of the rear doors contains these two additional fasteners.

e) Using both hands, lift the upper inner door panel until it releases from the metal ridge along the window line. It doesn’t take much effort to remove the upper panel as it slides off vertically. Store it on the seats for safekeeping.

4) Remove the Lower Inner Door Panels as follows:

a) Using the #2 Phillips screwdriver, remove the sheet metal screw located at the upper edge of the lower panel.

b) Using a ½”small wooden dowel or equivalent drift, place it under the lower edge of the door handle screw access cover. Lightly tap each end of the access cover using the dowel and mallet in an upward direction to release the access cover. These covers can be tight if they have never been removed in the past, but they will release.

c) Using the #2 Phillips screwdriver, remove the sheet metal screw located in the middle of the door handle.

d) Using a small awl or equivalent, remove the bottom door light lens by releasing it from its locator at the rear and sliding it outwards from the door.

e) Using the #2 Phillips screwdriver, remove the lower panel securing sheet metal screw located in the middle of the bottom door light assembly. All sheet metal screw fasteners for the lower panel are now removed.

f) Using both hands (and the large flat screwdriver, if needed), carefully pull off the lower inner door panel by release the series of fir-tree type press-fit connectors along the sides and lower perimeter. Once the panel is removed, it can be laid horizontally on the seat as there is sufficient length of wire bundle to allow this movement. It is not necessary to disconnect the wiring harness, but if desired, the connectors can be released so that the panel can be moved to another more worker friendly location.

5) Remove Door Mounted Speaker as follows:

a) Disconnect the speaker positive and negative conductors by releasing the electrical connector.

b) Using the 9mm Nutdriver, remove the speed clip nut from each of the four (4) speaker fastener studs. Press the nutdriver down firmly to engage the speed nut … do NOT cut away any foam material as it is not necessary.

c) Using the #2 Phillips screwdriver, remove the sheet metal screw immediately to the left (driver side) or right (passenger side) of the speaker as viewed from the back side of the door lower inner panel.

d) Using the #2 Phillips screwdriver, remove the sheet metal screw immediately above the speaker. It is located just below the upper sheet metal screw securing tab on the lower panel … the screw was previously removed in Step 4a.

e) Using the #2 Phillips screwdriver, remove the sheet metal screw immediately to the lower right (driver side) or lower left (passenger side) of the speaker as viewed from the back side of the door lower inner panel.

f) Using the #2 Phillips screwdriver, remove the sheet metal screw immediately to the lower far right (driver side) or lower far left (passenger side) of the speaker as viewed from the back side of the door lower inner panel.

g) Steps 5c, d, e and f will release the speaker / window lift pushbutton panel from the lower door inner panel. Removal of the sheet metal screws will allow the speaker panel to be pulled away from the lower panel by 3” to 4” to facilitate access for speaker removal.

h) With the speaker / window lift pushbutton panel eased back for working clearance, grasp the speaker with one hand while pressing the four (4) speaker studs downward through the foam supporting material. After the studs are clear from the foam material, the speaker can be removed from the panel.

6) Install New Door Mounted Speaker as follows:

Typically, base XJ40 models use 3.5” door speakers while the VDPs will use 4” door speakers. Though I believe it is possible to mount either type in either model.

a) Using the wiring supplied with the new speakers and insulated solderless **** splices, transfer the old speaker wiring electrical connector to the new speaker. Another alternate method is to simply solder the old speaker wires with connector to the new speaker terminals. This is a superior method for electrical continuity and strength of joint … although it does require some soldering skills.

b) Install the new 3.5” speaker by easing back the speaker panel and sliding in the new speaker. Normally, the 3.5” models will mount with only two fasteners.

c) Using two of the small machine screws with flat washers, place these fasteners through the speaker mounting lugs and press them up through the existing holes in the foam supporting material. Secure the screws with flat washers and matching nuts from the back side of the inner door panel. The use of thread locking compound (Loctite) is a nice touch to prevent loosening due to vibration.

d) Re-install the sheet metal screws removed in Steps 5c, d, e and f. This will re-mount the speaker panel. Don’t forget to re-connect the speaker wire connector at the door panel.


7) Re-installation of the inner door lower and upper panels is literally a reverse of the removal procedure. No hidden tricks.

8) Perform Steps 3 through 6 for the other doors and the job is complete.

9) Remove Rear Footwell Mounted Speaker as follows:

This sequence is good for both 4” and 5.25” footwell mounted woofers.

a) Using a small flat screwdriver as a lever, carefully ease off the grill.

b) Using a #2 Phillips screwdriver, remove the four (4) sheet metal mounting screws.

c) Ease out the old speaker and release the electrical connector for the speaker wires.

d) Transfer the old speaker wires and electrical connector to the new speaker using solderless **** splices or by soldering the old leads to the new speaker terminals.

e) Re-connect the speaker wires to the harness by joining the electrical connector.

f) Mount the new speaker and re-attach the necessary sheet metal screws.

g) Press the speaker grill into place.

h) Repeat Steps 9a though 9g for the other footwell speaker.

I believe that your speaker covers are clipped in through the back of the panel and won't come out through the front without breaking some of the clips. The proper way would be to remove the door panels and remove the covers out the back of the panel.

On the inside trim, you can remove screws that are by the door handle, arm rest, under door and side of door and then gently pull back on the panel as there will also be retaining clips attached and you don't want to break them. You'll need to lift the door panel upwards in order to get it off the window ledge. Then you'll need to manipulate the panel and disconnect the door handle linkage from the door handle and disconnect the wiring for your controls. Then you can remove the panel

First you remove the small triangular shaped plastic piece that is on top of the door panel by the front of the door by the mirror by simply prying it of. Next behind the door open lever if there is a small plastic cover remove it under it will be a screw. Next your window switch will just pry up and out, disconnect the wiring, under the switch there will be a screw ataching the door panel to the door. Next on the face of the door panel if there is a small cover about the size of a nickle but elongated, remove the cover and remove the screw below it. Next pry the door panel from the bottom untill it "pops" out and grab it and pop the rest of the panel out, lift the panel up off of the window ledge.

Removal and Installation

Remove the front door speaker. For additional information, refer to Section 415-00.
Remove the speaker watershield.
Remove the 2 speaker standoffs.
If equipped, remove the window regulator handle.
Separate the handle cover from the handle.
Remove the screw.
Remove the window regulator handle.
Remove the spacer.

Remove the window control switch. For additional information, refer to Section 501-11.
Remove the bolt.
Remove the 2 front door lower bolts.
Remove the door handle cover plate.
Remove the 2 door handle screws.
Remove the front door handle.
Guide the door handle through the opening in the trim panel.
CAUTION: Do not pull directly outward on the front door trim panel, as damage may occur.

Remove the front door trim panel.
Lift upward to remove the front door trim panel.
To install, reverse the removal procedure.

You have to remove the speaker cover under the screen and controls. It says Mitsubishi on it. The speaker cover pulls off. There are some screws under the control panel that have to be taken out. Then follow the 2 sets of wires from the control panel and unplug them. You can then lift the screen up and it should come off.

[email protected]