Chevrolet Silverado / GMC Sierra. Manual - part 1308

Fig. 144: Drilling Plug Weld Holes 
Courtesy of GENERAL MOTORS CORP. 

1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the 

original panel.  

2. Prepare all attachment surfaces as necessary.  

3. Prepare all mating surfaces as necessary.  

4. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion 

Treatment and Repair .  

5. Position the service part. Clamp in place. 

IMPORTANT: If the location of the original plug weld holes can not be determined, 

space the plug weld holes every 40 mm (1 1/2 in) apart. Where structural 
adhesive was present, space the plug weld holes every 20 mm (3/4 in) 
apart.

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:01 PM

Page 158 

© 2005 Mitchell Repair Information Company, LLC. 

Fig. 145: View Of Plug Welding 
Courtesy of GENERAL MOTORS CORP. 

6. Plug weld accordingly.  

7. Clean and prepare all welded surfaces.  

8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion 

Treatment and Repair .  

9. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .  

10. Install all related panels and components.  

11. Connect 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) .  

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

DESCRIPTION AND OPERATION 

METAL PANEL BONDING 

This is intended to provide general guidelines for adhesive bonding of exterior panels as an alternative to Metal-
Inert Gas (MIG) welding. Panel bonding may be seen as an alternative to MIG welding to provide full panel 
replacement in regards to collision repair procedures. The benefits of panel bonding is: 



No heat or burn damage when additional welding is not required 

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:01 PM

Page 159 

© 2005 Mitchell Repair Information Company, LLC. 



Corrosion protection  



Can act as a sealant  



Improved process for complicated shapes (wheelhouse area)  

The General Motors specification for metal bonding adhesives is GM 6449G. The scope of this specification is 
intended to provide the performance guidelines of structural adhesive systems used to repair (metallic) 
automotive bodies in the aftermarket. These types of adhesives are intended for use when bonding replacement 
body panels as an option to welding as the attachment means. GM information outlines the use of room 
temperature cure acrylic adhesives that contain glass bead technology. 

Bonding procedures in general are applicable only to a factory seams type approach. 

Sectioning or partial paneling of full panels is not supported by General Motors unless specifically documented 
in a Service Bulletin or Manual. 

Applicable components for this technology are EXTERIOR PANELS ONLY, including door skins, tail panels, 
roof outer panels and quarter panels. 

Adhesives currently meeting the performance requirements include General Motors materials and products 
manufactured by Lord Adhesives. At this time, ONLY the adhesive products listed below meet this guideline: 

IMPORTANT: Do not use adhesives for vehicle underbody or upper body structure type 

repairs such as structural rails, shock/strut towers, floor pans, upper fender 
rails, body side pillars, door rings-side or rear, rocker panels, unless 
specifically documented in a GM Service Bulletin or Manual. If in doubt, use 
only the procedures referenced in the Service Manual for the specific vehicle 
being repaired. 
Always follow the system manufacturer's instructions for application, handling, 
and curing.

Manufacturer and Part Number

Description

GM P/N 12378566 (US)

Fast Set Panel Bonding Adhesive

GM P/N 88901674 (Canada)

Lord Fusor P/N 110B/111B

GM P/N 12378567 (US)

Medium Set Panel Bonding Adhesive

GM P/N 88901675 (Canada)

Lord Fusor P/N 108B/109B

3M P/N 8116

Panel Bonding Adhesive

Ashland Plio Grip Panel 60

Panel Bonding Adhesive

 

2008 Chevrolet Silverado 1500 

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

Silverado

  

Microsoft 

 

Friday, August 21, 2009 2:21:01 PM

Page 160 

© 2005 Mitchell Repair Information Company, LLC. 

2008 ENGINE 

Cruise Control - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado 

SCHEMATIC AND ROUTING DIAGRAMS 

CRUISE CONTROL SCHEMATICS 

Fig. 1: Cruise Control Schematic 
Courtesy of GENERAL MOTORS CORP. 

DIAGNOSTIC INFORMATION AND PROCEDURES 

DIAGNOSTIC CODE INDEX 

DIAGNOSTIC CODE INDEX 

DTC

Description

DTC B3794

B3794 08: Cruise Control Function Request Circuit Signal 

Invalid 

B3794 61: Cruise Control Function Request Circuit Actuator 

 

2008 Chevrolet Silverado 1500 

2008 ENGINE Cruise Control - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

  

 

2008 Chevrolet Silverado 1500 

2008 ENGINE Cruise Control - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado

  

 

 

 

 

 

 

 

Content   ..  1306  1307  1308  1309   ..