Tools You'll Likely Need:
* Socket set: Various sizes, including metric and possibly SAE.
* Wrench set: Similar to the sockets.
* Screwdrivers: Phillips and flathead, various sizes.
* Pliers: Needle-nose and regular.
* Hammer: Rubber mallet is preferred to avoid damage.
* Jack and jack stands: Essential for safety.
* Wheel chocks: For added safety.
* Ratcheting wrench: Makes things easier.
* Penetrating oil (like PB Blaster): To loosen rusted bolts.
* Shop rags or towels: To clean up and protect surfaces.
* Possibly a rivet gun/drill: Depending on how the fender is attached.
General Steps:
1. Safety First: Park the van on a level surface, engage the parking brake, and use wheel chocks. Jack up the van and securely support it with jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the wheel on the side of the fender you're removing. This provides better access.
3. Disconnect Electrical Connections: Inspect the fender area for any wiring harnesses or electrical connectors (like for the headlights, turn signals, etc.). Carefully disconnect these. Take pictures or make notes to ensure you reconnect them correctly.
4. Remove Fasteners: This is the most labor-intensive part. The fender is likely attached with:
* Bolts: Located along the wheel well, under the hood, and possibly at the bottom edge. Use penetrating oil to loosen any stubborn bolts.
* Screws: Similar locations to the bolts.
* Rivets: Some fenders might use rivets instead of bolts or screws, requiring drilling them out. This is more permanent and requires replacing them upon reassembly.
* Plastic Clips: These often hold the fender liner and other trim pieces. Carefully pry them off using a flathead screwdriver or trim removal tool.
5. Separate the Fender: Once all fasteners are removed, carefully separate the fender from the van body. There might be some resistance from rust or paint. Gently work the fender free, taking care not to damage surrounding parts.
6. Lower the Van: Carefully lower the van using the jack.
Important Considerations:
* Rust: A 1990 van is likely to have some rust, especially in the fender area. This will make the removal process more challenging.
* Fender Liner: You'll likely need to remove the inner fender liner to access all the fasteners.
* Reassembly: Remember to take pictures or make notes during the disassembly process so you can easily reassemble everything correctly. It’s very easy to get lost without notes.
Again, consult a repair manual specific to your 1990 Chevy van model for precise instructions and diagrams. This is a general guide, and the exact procedures may differ. If you're not comfortable with this type of repair, it's best to take it to a qualified mechanic.
