GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

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 trim panel. Refer to Front Side Door Trim Panel Replacement
  2. Remove the energy absorber pad. Refer to Front Door Energy Absorber Pad Replacement
  3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement

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

  9. Object Number: 308317  Size: SH
  10. Remove the outside door handle bolts.

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

Installation Procedure

  1. Install the lock rod to the handle.
  2. Position the handle to the door.

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

  5. 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.

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

  8. Install the key cylinder rod to the handle.

  9. Object Number: 293875  Size: SH
  10. Snap a new outside handle rod-to-lock clip onto the door lock lever.
  11. Position the outside door handle rod in the clip eliminating any free play in the outside door handle.
  12. Snap the clip cover closed over the threaded part of the outside door handle rod.
  13. Install the water deflector. Refer to Front Side Door Water Deflector Replacement
  14. Install the energy absorber pad. Refer to Front Door Energy Absorber Pad Replacement
  15. Install the trim panel. Refer to Front Side Door Trim Panel Replacement