Door Panel Removal

[[email protected]]

How do I remove the door panel on an 06 Express. I need help getting the arm rest apart as I am sure that needs to come off to get to the screws. I have removed the 2 screws under the cover at the inside door handle. What is next?

Thanks,

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 751956 Fastener Tightening Specifications

Application

Specification

 

Metric

English

 

Camper Mirror Head to the Braces Bolt

37 N·m

27 lb ft

 

Camper Rearview Mirror Arm and Braces to the Door Bolts

4 N·m

35 lb in

 

Commercial Mirror Head to the Braces Bolts

5 N·m

44 lb in

 

Commercial Mirror Lower Bracket to the Door Bolts

4 N·m

35 lb in

 

Commercial Mirror Pivot Arm Nuts

12 N·m

106 lb in

 

Commercial Mirror Upper Brackets to the Door Nuts

4 N·m

35 lb in

 

Door Hinge to the Door or Pillar Bolts

25 N·m

18 lb ft

 

Door Latch Handle to the Door Nuts

11 N·m

97 lb in

 

Door Latch to the Door Bolts

25 N·m

18 lb ft

 

Door Lock Striker to the Door Opening or the Door Bolts

10 N·m

89 lb in

 

Door Lock to the Door Bolts/ Screws

10 N·m

89 lb in

 

Door Wedges to the Door or the Door Openings

10 N·m

89 lb in

 

Front Door Armrest Retaining Screw

1.9 N·m

17 lb in

 

Front Door Hinge Nuts and Bolts

35 N·m

25 lb ft

 

Front Door Link to the Door Jamb Bolts

11 N·m

97 lb in

 

Front Door Link to the Door Nuts

11 N·m

97 lb in

 

Front Door Trim Plate Retaining Screws

1.9 N·m

17 lb in

 

Lock to the Door Screws

10 N·m

89 lb in

 

Outside Door Handle to the Door Nuts

10 N·m

89 lb in

 

Power Window Motor to the Front Door Module Nuts

11 N·m

97 lb in

 

Rearview Mirror Filler to the Door Nuts

10 N·m

89 lb in

 

Rearview Mirror to the Door Nuts

10 N·m

89 lb in

 

Run Channel to the Door Bolt

11 N·m

97 lb in

 

Side Door Lower Striker to the Stepwell Bolts

10 N·m

89 lb in

 

Side Door Upper Striker to the Door Opening Bolts

10 N·m

89 lb in

 

Side Front Door Assist Handle Retaining Screws

1.9 N·m

17 lb in

 

Side Front Door Check Strap Bolts

10 N·m

89 lb in

 

Side Front Door Trim Plate Retaining SCrew

1.9 N·m

17 lb in

 

Sliding Side Door Center Track Bolts

11 N·m

97 lb in

 

Sliding Side Door Center Track Sliding Side Door Stop to the Body Nut

25 N·m

18 lb ft

 

Sliding Side Door Control Assembly to the Door Bolts

10 N·m

89 lb in

 

Sliding Side Door Front and Rear Striker Bolts

24 N·m

18 lb ft

 

Sliding Side Door Locator Mounting Bolts

10 N·m

89 lb in

 

Sliding Side Door Lower Track Bolts

11 N·m

97 lb in

 

Sliding Side Door Roller/Bracket Nuts and Bolts

25 N·m

18 lb ft

 

Sliding Side Door Stop Nut

25 N·m

18 lb ft

 

Sliding Side Door Wedge Mounting Bolts

10 N·m

89 lb in

 

Window to the Sash Retaining Nuts

11 N·m

97 lb in

[jrrod2004]

by the way, are you referring to the cargo side door or the front driver and front passenger door?

[[email protected]]

by the way, are you referring to the cargo side door or the front driver and front passenger door?

 

 

I am sorry that is the front drivers door. I have to replace the outside door handle.

[jrrod2004]

I am sorry that is the front drivers door. I have to replace the outside door handle.

 

Give me a couple of mins to pull the front door handle information

 

 

 

and by the way, none of the links will work on the documents I post. I will include the relevant information for you to complete the repair

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 815102 Door Outside Handle Replacement

Removal Procedure

 

1. Raise the window completely.
   
2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
   
3. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
   
    
   
4. Remove the lock rods (2) from the lock (6).
   
5. Remove the rear run channel from the door. Refer to Window Channel Replacement .
   
6. Remove the nuts (8) and the bracket (7) that retain the outside door handle (1) to the door.
   
7. Remove the outside door handle (1) from the door.
   

Installation Procedure

 

1. 
   
    
   
2. Install the outside door handle (1) to the door.
   
3. Install the nuts (8) and the bracket (7) in order to retain the handle (1) to the door.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.
    
   
4. Install the nuts (8) that retain the outside door handle (1) to the door.Tighten
   Tighten the retaining nuts to 11 N·m (97 lb in).
    
   
5. Install the rear run channel to the door. Refer to Window Channel Replacement .
   
6. Install the lock rods (2) to the lock (6).
   
7. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
   
8. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 889021 Front Side Door Trim Panel Replacement

Tools Required

J 38778 Door Trim Pad and Garnish Clip Remover

 

Removal Procedure

 

1. 
   
    
   
2. Remove the front door garnish molding. Refer to Front Side Door Front Garnish Molding Replacement .
   
3. Remove the front door trim plate. Refer to Front Door Trim Plate Replacement .
   
4. Remove the armrest (3). Refer to Armrest Replacement .
   
5. Remove the door trim panel screws (2), located behind the armrest.
   
6. Use the J 38778 to disengage the retainers around the outside edges of the door trim panel (1).
   
7. Slide the door trim panel (1) upwards to release the door panel from the door.
   
8. Remove the front door panel (1) from the vehicle.
   

Installation Procedure

 

1. 
   
    
   
2. Install the door trim panel (1), by hooking the top of the door trim panel (1) to the door belt line.
   
3. Align the door trim panel retainers to the door.
   
4. Push towards the door to engage the retainers to the sheet metal.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.
    
   
5. Install the door trim panel screws (2).Tighten
   Tighten the screw (2) to 2.0 N·m (18 lb in).
    
   
6. Install the armrest (3). Refer to Armrest Replacement .
   
7. Install the front door trim plate. Refer to Front Door Trim Plate Replacement .
   
8. Install the front door garnish molding. Refer to Front Side Door Front Garnish Molding Replacement .
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 752057 Front Side Door Front Garnish Molding Replacement

Removal Procedure

 

1. 
   
    
   
2. Grasp the front door front garnish molding.Gently pull at the top of the molding in order to disengage the retaining clips.
    
   
3. Lift the front door front garnish molding up to disengage the tab on the garnish molding from the slot on the door trim panel.
   
4. Inspect the front door front garnish molding for broken or missing retaining clips. Replace any clips, if needed.
   

Installation Procedure

 

1. 
   
    
   
2. Install the front door front garnish molding to the vehicle.
   
3. Insert the tab on the bottom of the garnish molding into the slot at the top of the door trim panel.
   
4. Align the retainers on the front door front garnish molding with the slots in the door.
   
5. Push on the molding in order to engage the retainers.
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 885377 Front Door Trim Plate Replacement

Removal Procedure

 

1. 
   
    
   
2. Remove the window regulator handle, if equipped. Refer to Door Window Regulator Handle Replacement .
   
3. Remove the inside door handle bezel. Refer to Front Side Door Inside Handle Bezel Replacement .
   
4. Remove the screws (2) that retain the front door trim plate (1) to the door panel.
   
5. Pull the bottom of the front door trim plate (1) out in order to release the front door trim plate (1) retainers.
   
6. Remove the front door trim plate from the front door trim panel.
   
7. Disconnect the electrical connectors from the switches on the front door trim plate, if equipped.
   
8. Remove the front door trim plate (1) from the vehicle.
   

Installation Procedure

 

1. 
   
    
   
2. Partially install the front door trim plate (1) to the front door trim panel.
   
3. Connect the electrical connectors to the switches, if equipped.
   
4. Align the retainers on the front door trim plate (1) to the slots in the front door trim panel
   
5. Push towards the door panel to engage the front door trim plate (1) retainers.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 screws (2).Tighten
   Tighten the screw that retains the front door trim plate to 1.9 N·m (17 lb in)
    
   
7. Install the inside door handle bezel. Refer to Front Side Door Inside Handle Bezel Replacement .
   
8. Install the window regulator handle, if equipped. Refer to Door Window Regulator Handle Replacement .
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 896960 Door Window Regulator Handle Replacement

Tools Required

J 9886-01 Door Handle Clip Remover

 

Removal Procedure

 

1. Note the position of the door window regulator handle with the window in the full up position.
   
2. Place the door window regulator handle in the upward position.
   
    
   
3. Remove the spring clip by inserting J 9886-01 between the window regulator handle and the door window regulator handle bearing plate. Press down to remove the spring clip.
   
4. Remove the window regulator handle.
   
5. Remove the door window regulator handle bearing plate.
   

Installation Procedure

 

1. Position the window to the full up position.
   
    
   
2. Install the spring clip (2) to the door window regulator handle (1).
   
3. Install the door window regulator handle (1) bearing plate.
   
4. Position the door window regulator (1) handle to the regulator.
   
5. Install the door window regulator handle (1), press in until fully seated.
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 885373 Front Side Door Inside Handle Bezel Replacement

Removal Procedure

 

1. 
   
    
   
2. Press the retaining tab on the inside door handle bezel (1) in order to release the inside door handle bezel (1) from the front door trim plate.
   
3. Remove the inside door handle bezel (1) from the vehicle.
   

Installation Procedure

 

1. 
   
    
   
2. Align the inside door handle bezel (1) to the front door trim plate.
   
3. Press the door handle bezel towards the door trim panel in order to engage the retaining tab.
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 885375 Armrest Replacement

Removal Procedure

 

1. 
   
    
   
2. Insert a flat bladed tool at the rear of the armrest (3).
   
3. Pull away from the door trim panel in order to disengage the armrest clips.
   
4. Remove the armrest (3).
   

Installation Procedure

 

1. 
   
    
   
2. Align the armrest (3) to the front door panel.
   
3. Press the armrest (3) towards the door trim panel in order to engage the armrest clips.
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 814740 Front Side Door Water Deflector Replacement

Removal Procedure

 

1. 
   
    
   
2. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
   
3. Remove the front door water deflector from the front door inner panel.
   
4. Remove the gasket from the inside door handle if equipped.
   
5. Pull the electrical connectors through the slit in the door handle cut out.
   

Installation Procedure

 

1. 
   
    
   
2. Align the front door water deflector to the front door inner panel. Secure the water deflector at the corners.
    
   
3. Pull the front door electrical connectors through the slit in the door handle cut out.
   
4. Install the front door water deflector, start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering.
   
5. Install the gasket to the inside door handle if equipped.
   
6. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
   

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 815196 Window Channel Replacement

Removal Procedure

 

1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
   
2. Remove the front door rear garnish. Refer to Front Side Door Rear Garnish Molding Replacement .
   
3. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
   
4. Lower the front door window.
   
5. Remove the inner window sealing strip. Refer to Front Side Door Upper Auxiliary Sealing Strip Replacement .
   
6. Remove the outer window sealing strip. Refer to Outer Belt Sealing Strip Replacement .
   
    
   
7. Remove the bolt (2) that retains the front run channel (1) to the door.
   
8. Remove the front run channel (1) from the door.
   
9. Raise the front window approximately half way in order to access the nuts that retain the front door window to the sash. Access the nuts through the holes in the front door module.
   
10. Remove the nuts that retain the front door window to the sash.
    
     
    
11. Remove the front door window from the door from the outside of the vehicle.
    
12. Remove the bolt (2) that retains the rear run channel (1) to the door.
    
13. Remove the rear run channel (1) from the door.
    

Installation Procedure

 

1. 
   
    
   
2. Install the rear run channel (1) to the door.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.
    
   
3. Install the bolt (2) in order to retain the rear run channel (1) to the door.Tighten
   Tighten the retaining bolt to 11 N·m (97 lb in).
    
   
4. Install the front door window to the door from the outside of the vehicle.
   
    
   
5. Install the nuts (3) in order to retain the front door window to the sash.Tighten
   Tighten the retaining nuts to 11 N·m (97 lb in).
    
   Important: Before raising or lowering the front door window ensure that the front door window is properly aligned in the rear run channel.
    
   
6. Lower the front door window.
   
7. Install the front run channel (1) to the door.
   
8. Install the bolt (2) in order to retain the front run channel (1) to the door.Tighten
   Tighten the retaining bolt to 11 N·m (97 lb in).
    
   
9. Install the inner window sealing strip. Refer to Front Side Door Upper Auxiliary Sealing Strip Replacement .
   
10. Install the outer window sealing strip. Refer to Outer Belt Sealing Strip Replacement .
    
11. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
    
12. Install the front door rear garnish. Refer to Front Side Door Rear Garnish Molding Replacement .
    
13. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
    

© 2008 General Motors Corporation. All rights reserved.

[jrrod2004]

Service Information

 

2006 Chevrolet Express | Express, Savana (VIN G/H) Service Manual | Document ID: 752059 Front Side Door Rear Garnish Molding Replacement

Removal Procedure

 

1. 
   
    
   
2. Grasp the front door rear garnish molding.Gently pull the molding in order to disengage the retaining clips.
    
   
3. Remove the front door rear garnish molding from the vehicle.
   
4. Inspect the front door rear garnish molding for broken or missing retaining clips. Replace any clips, if needed.
   

Installation Procedure

 

1. 
   
    
   
2. Install the front door rear garnish molding to the vehicle.
   
3. Align the retainers on the front door rear garnish molding with the slots in the door.
   
4. Push on the molding in order to engage the retainers.
   

© 2008 General Motors Corporation. All rights reserved.