Door Handle – Removal, Installation, and Adjustment – 2.5L NA

Overview

This procedure covers the removal, installation, and adjustment of the exterior door handle on a Porsche 944 with a 2.5L naturally aspirated engine, for both pre-1985.5 and 1985.5 onwards models. The door handle allows you to open the door from the outside, and a properly adjusted handle ensures smooth operation. Issues like a stiff or inoperative handle may stem from misadjusted linkage or striker plates, which this guide addresses. For vehicles with electric door locks (common in 85.5 onwards models), additional steps are required to disconnect wiring, which involves removing the door panel.

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Tools Required

• Phillips head screwdriver
• Long, thin flathead screwdriver (blade approximately 3mm (1/8 inch) wide)
• Flathead screwdriver with a thicker blade (approximately 6mm (1/4 inch) wide)
• Flashlight
• 5mm (3/16 inch) Allen head socket or Allen key (for striker plate adjustment)

Parts Required

• Rear door handle gasket – 944 537 631 00
• Small front door handle gasket – 944 537 091 00
• Replacement door handle (if needed) – 944 537 061 03 (left) or 944 537 062 03 (right)

Step-by-Step Procedure

Step 1: Remove the Door Handle

1. (85.5 Onwards) If your vehicle has electric door locks, you must remove the door panel to disconnect the wiring to the door handle. Follow this link to ensure this step – Door Panel Removal – is followed accurately.
2. Locate the Phillips head screw just above the door latch mechanism, inside the door frame. Use a Phillips head screwdriver to remove this screw and set it aside.

3. From the outside of the car, slide the door handle toward the front of the vehicle to disengage it from the door. Then, gently pull the handle outward, away from the door.

4. Inspect the back of the door handle. You’ll see a white plastic piece attached to a button on the lock mechanism. Using a thin flathead screwdriver (3mm (1/8 inch)), carefully pry this white plastic piece off the button.

5. Locate the linkage rod connected to the door handle, which attaches to a ball on the latch mechanism via a plastic socket. Insert a long, thin flathead screwdriver between the linkage rod and the latch mechanism. Gently pry while rocking the door handle back and forth to pop the socket off the ball.
6. Remove the door handle completely from the vehicle.

Step 2: Adjust the Door Handle Linkage (If Needed)

7. If the door handle doesn’t operate the latch (but the interior handle works), the linkage may need adjustment. Test the handle off the car to confirm the linkage moves downward when pulled.
8. Locate the plastic socket at the end of the linkage rod. To lengthen the linkage, turn this socket counterclockwise by hand or with a flathead screwdriver. Adjust in small increments (e.g., one full turn) to avoid overextending.
9. Reattach the handle temporarily (see Step 3 below) to test the adjustment. Repeat until the latch operates smoothly.

Step 3: Adjust the Striker Plate (If Needed)

10. If the door is hard to open or close, the striker plate may be misaligned. Open the door and locate the striker plate on the door frame, secured by three 5mm (3/16 inch) Allen head bolts.
11. Using a 5mm (3/16 inch) Allen head socket or key, slightly loosen all three bolts, but don’t remove them.
12. With the door almost closed, use a flashlight to check the latch’s alignment with the striker bar. The latch should be nearly centered on the bar. Adjust the striker plate’s position by moving it slightly (e.g., 1-2mm (1/16 inch)) up, down, or sideways.
13. Tighten the bolts to 10 Nm (7.4 ft-lbs) and test the door’s operation. Repeat adjustments in small increments until the door closes smoothly.

Step 4: Install the Door Handle

14. Check the white plastic piece inside the door’s handle opening (connected to the lock mechanism). It should point upward, visible in the larger handle opening. If it’s pointing down, use a flathead screwdriver to rotate it up.

15. Install the rear door handle gasket (944 537 631 00) onto the new or existing door handle.
16. Angle the door handle to insert the linkage rod into the door’s handle opening. Maneuver it carefully to align the rod inside the door.

17. Align the plastic socket on the linkage rod with the ball on the latch mechanism. Use a thicker flathead screwdriver (6mm (1/4 inch)) to press the socket onto the ball while rocking the handle gently until it snaps into place.
18. Push the door handle into the opening far enough to reattach the white plastic piece to the lock mechanism’s button. Press it on with your finger or a flathead screwdriver if needed.
19. Install the small front door handle gasket (944 537 091 00) onto the front of the door handle.
20. Insert the front of the door handle into the door’s opening, then press the rear of the handle to seat it fully.
21. Slide the door handle toward the rear of the car until it stops.
22. Reinstall the Phillips head screw above the latch mechanism using a Phillips head screwdriver.

Post Procedure Checklist

• Test the door handle from the outside to ensure it opens the door smoothly.
• Check the door lock by locking and unlocking it with the key to confirm proper operation.
• Close the door and verify it latches securely without excessive force.
• Inspect the handle and gaskets for proper seating, with no gaps or looseness.
• (85.5 Onwards) If the door panel was removed, confirm all electrical connections (e.g., door locks) function correctly after reassembly.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube