Before you begin:
* Disconnect the battery negative terminal. This is crucial to prevent accidental shorts or damage to electrical components.
* Gather your tools: You'll likely need a trim panel removal tool (plastic pry tool is best to avoid scratching), a Phillips head screwdriver, and possibly a Torx screwdriver (check your door for screw types).
Steps:
1. Remove the interior door handle: There are usually screws hidden under the armrest/door pull area. You may need to carefully pry off the armrest or similar panel to access these screws. Once the screws are removed, the interior handle assembly should detach.
2. Remove the window crank/power window switch bezel: This is usually held in place by screws or clips. Carefully pry it off using your trim tool. Disconnect the electrical connector to the power window switch.
3. Remove the door lock/unlock switch bezel (if separate from the window switch): This typically involves similar steps as removing the window switch bezel. Disconnect the electrical connector.
4. Remove the door panel itself: This is where careful prying is key. Start at the bottom of the door panel. There are usually plastic clips holding the panel in place. Work your way around the perimeter of the door panel, carefully inserting your trim tool between the panel and the door, popping the clips free. Do not force anything. If you encounter resistance, try a different spot. There might be screws hidden behind other components that need to be removed first.
5. Disconnect the electrical connectors: Once the panel is mostly loose, carefully disconnect any remaining electrical connectors, such as the power lock actuator connector and possibly others related to the courtesy light.
6. Remove the door panel completely: Once all the clips are released and connectors disconnected, carefully pull the door panel away from the door.
Important Considerations:
* Clips: These are usually plastic and can break easily. Try to work gently and use a plastic pry tool. Replacement clips are readily available at auto parts stores.
* Wiring: Be mindful of the wiring harnesses. Don't pull too hard on them.
* Manual vs. Power: The process might differ slightly if you have manual windows/locks versus power. Power options will have additional electrical connectors.
Reassembly:
Reassembly is generally the reverse of disassembly. Make sure all clips are properly engaged and all electrical connectors are securely connected before reinstalling the door panel. Test the power locks and windows to ensure everything is working correctly.
This is a general guide. Again, consult a repair manual specific to your 1990 Chevy G-20 van for the most accurate and detailed instructions. A visual guide (YouTube video, for example) might also be very helpful. Searching for "1990 Chevy G20 door panel removal" on YouTube should yield some results.
