Chevrolet Silverado / GMC Sierra. Manual - part 1280

or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .  

14. Enable the SIR system. Refer to SIR Disabling and Enabling .  

FRONT SIDE DOOR OUTER PANEL REPLACEMENT 

Removal Procedure 

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection 

(w/Single Battery) or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery) 
or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .  

2. Disable the SIR system. Refer to SIR Disabling and Enabling .  

3. Remove all related panels and components.  

4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.  

5. Remove the door assembly. Refer to Front Side Door Replacement . 

CAUTION: Refer to Approved Equipment for Collision Repair Caution .

IMPORTANT: Before beginning the repair, refer to Metal Panel Bonding for proper 

adhesive applicator preparations and general information.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

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Fig. 42: Drilling Out Outer Front Door Panel Factory Welds 
Courtesy of GENERAL MOTORS CORP. 

6. Locate and drill out all factory welds. Note the number and location of welds for installation of the 

service panel. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

Page 47 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 43: Grinding Outer Door Panel Edges 
Courtesy of GENERAL MOTORS CORP. 

7. Grind the edges of the door outer panel to separate the outer door panel from the door shell. 

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

Page 48 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 44: View Of Outer Door Panel 
Courtesy of GENERAL MOTORS CORP. 

8. Remove the outer door panel.  

9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-

Corrosion Treatment and Repair .  

10. Straighten the edges of the door shell.  

Installation Procedure 

CAUTION: Inspection of the door guard beam for damage must be performed 

before replacement of the door outer panel. If damage to the door 
guard beam is found the door must be replaced. Failure to do so may 
compromise the structural integrity of the vehicle and may cause 
personal injury if the vehicle is involved in a collision.

 

2008 Chevrolet Silverado 1500 

2008 ACCESSORIES & EQUIPMENT Collision Repair - - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & 

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:20:59 PM

Page 49 

© 2005 Mitchell Repair Information Company, LLC.