GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Aztek - FWD 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Outside Handle Replacement

Removal Procedure

    Notice: When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent paint damage.

  1. Place tape around the handle to protect the paint.

    2. Important: The outside door handles have adjustable handle-to-lock rods. This allows for adjustment of the amount of travel needed to operate the outside door handle.

    It is important to remove all free play between the outside handle and the lock. Do NOT operate the outside handle before you have made these adjustments.

  2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
  3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .

    4. Object Number: 624645 Size: SH
  4. Disconnect the outside door handle rod-to-lock.

    5. Object Number: 621588 Size: SH
  5. Remove the center of the rivets using a center punch.

    6. Object Number: 621621 Size: SH
  6. Drill out the rivet from the front outside door handle using a 6.35-mm (1/4-in) drill bit.

    7. Object Number: 621617 Size: SH
  7. Remove the outside door handle from the front door.
  8. Remove the outside door handle from the door handle rod.

Installation Procedure

    Object Number: 621617 Size: SH
  1. Install the outside door handle to the door handle rod.
  2. Position the handle to the front door.

    3. Object Number: 621619 Size: SH
  3. Install the new rivets to the outside door handle.

    4. Object Number: 624647 Size: SH
  4. Connect the outside door handle rod-to-lock.
  5. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
  6. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .
  7. Remove the tape from around the handle.