GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

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

    When servicing a vehicle with adjustable outside handle lock rods, remove all free play between the outside handle and the lock. Also, do not operate the outside handle before these connections are made.

  1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
  2. Remove the front water deflector, as necessary. Refer to Front Side Door Water Deflector Replacement .
  3. Raise the window to the full up position.

  4. Object Number: 800969  Size: SH

    Notice: To avoid paint damage, protect the area surrounding the part which you are removing or installing.

  5. Apply masking tape around the outside handle.
  6. Open the outside handle rod to lock clip located on the door lock.
  7. Remove the lock cylinder rod from the outside door handle. Refer to Door Lock Cylinder Replacement .

  8. Object Number: 787538  Size: SH
  9. Remove the door handle bolt access plug (1) from the inner door panel.
  10. Remove the bolts (2) from the outside handle.

  11. Object Number: 787545  Size: SH
  12. Remove the outside handle (1) and rod (2) from the door.

Installation Procedure


    Object Number: 787545  Size: SH
  1. Install the outside handle (1) and rod (2) to the door.

  2. Object Number: 787538  Size: SH

    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.

  3. Install the outside handle bolts (2).
  4. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  5. Install the outside handle bolt access plug (1) to the inner door panel.
  6. Install the lock cylinder rod to the outside door handle. Refer to Door Lock Cylinder Replacement .

  7. Object Number: 800969  Size: SH

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

    When servicing a vehicle with adjustable outside handle lock rods, remove all free play between the outside handle and the lock. Also, do not operate the outside handle before these connections are made.

  8. Install the outside handle rod into the clip
  9. Close the clip cover over the outside handle rod.
  10. Inspect the outside handle for proper operation.
  11. Remove the masking tape.
  12. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
  13. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .