GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: Disconnect the power window switch when working inside the driver door. When operated, the Express Up/Down Feature allows the door window to move very quickly, without stopping, which could cause personal injury.

Caution: Disconnect the power window switch when working inside the driver door. When operated, the Express Up/Down Feature allows the door window to move very quickly, without stopping, which could cause personal injury.

Important: The outside handle lock rods allow adjustment of the free play between the outside handle and the door lock.

All free play between the outside handle and the lock must be removed when servicing the handle. 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 door water deflector. Refer to Front Side Door Water Deflector Replacement .

  3. Object Number: 293875  Size: SH
  4. Use side cutters to cut off the outside handle rod-to-lock clip from the lock.
  5. Unscrew the remainder of the handle rod-to-lock clip from the outside handle rod.
  6. Discard the rod-to-lock clip.
  7. Remove the lock rod from the lock.

  8. Object Number: 308317  Size: SH
  9. Remove the front door outside handle to door bolts.

  10. Object Number: 164527  Size: SH
  11. Rotate the lock cylinder pawl to allow the front door outside handle to clear the front door outside handle opening.
  12. Remove the lock rod from the front door outside handle.
  13. Remove the handle rod from the outside handle.

Installation Procedure

  1. Install the lock rod to the front door outside handle.
  2. Install the door handle rod.
  3. Position the front door outside handle to the front door.

  4. Object Number: 164527  Size: SH
  5. Rotate the lock cylinder pawl in order to allow the front door outside handle to clear the front door outside handle opening.

  6. Object Number: 308317  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.

  7. Install the front outside door handle bolts.
  8. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  9. Install the lock cylinder rod to the front door outside handle.

  10. Object Number: 293875  Size: SH
  11. Align a new front door outside handle rod-to-lock clip onto the door lock lever.
  12. Apply pressure to the rod-to-lock clip until fully seated.
  13. Position the outside door handle rod in the rod-to-lock clip eliminating any free play in the outside door handle.
  14. Apply pressure to the rod-to-lock clip until fully seated.
  15. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
  16. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .