GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Body 🢒 Doors 🢒 Door Outside Handle Replacement

Removal Procedure

    Object Number: 1218945 Size: SH
  1. Remove the plug (1) to expose the T25 TORX head set bolt.
  2. Remove the bolt under the plug (1).
  3. Remove the outside cap (2).

    4. Object Number: 1218955 Size: SH
  4. Pull the outside handle (1) rearward and out of the door. Remove the outside handle.

    5. Object Number: 1218975 Size: SH
  5. Pull the gaskets (1) off the door.

    6. Object Number: 1218979 Size: SH
  6. Remove the T25 TORX head bolt (1). Remove the handle housing.
  7. Remove the trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side Door Trim Panel Replacement .
  8. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement or Rear Side Door Water Deflector Replacement .
  9. Remove the lock cylinder. Refer to Door Lock Cylinder Replacement .

    10. Object Number: 1218256 Size: SH
  10. Remove the handle rod from the lock.

    11. Object Number: 1223892 Size: SH
  11. Remove the door handle rod (1) from the housing (2).

Installation Procedure

    Object Number: 1223892 Size: SH
  1. Install the door handle rod (1) to the housing (2).

    2. Object Number: 1223874 Size: SH
  2. Install the handle rod to the lock.

    3. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1218979 Size: SH
  3. Install the T25 TORX bolt (1) to the handle housing.

    4. Tighten
    Tighten the bolt to 3 N·m (27 lb in).


    Object Number: 1218975 Size: SH
  4. Install the handle and cap gaskets (1).

    5. Object Number: 1218955 Size: SH
  5. Position the outside handle into the door. Slide the handle forward.
  6. Install the lock cylinder. Refer to Door Lock Cylinder Replacement .

    7. Object Number: 1218945 Size: SH
  7. Install the TORX head cap. Install the T25 TORX head bolt from the door frame side.

    8. Tighten
    Tighten the bolt to 3 N·m (27 lb in).

  8. Install the TORX plug.
  9. Install the water deflector. Refer to Front Side Door Water Deflector Replacement or Rear Side Door Water Deflector Replacement .
  10. Install the trim panel. Refer to Front Side Door Trim Panel Replacement or Rear Side Door Trim Panel Replacement .