Regan Brown
Replacing the fuel door on a 2005 Silverado is a straightforward process. This guide will take you through the steps, from opening the original fuel door to installing the new one. You'll need a 1/4 drill bit to drill out the rivets, and you'll also need to remove the rubber fuel door stops and the plastic shroud. After that, it's just a matter of tightening the nuts on the adapter and installing the new door.
| Characteristics | Values |
|---|---|
| Step One | Open the original fuel door |
| Step Two | Using a 1/4" drill bit, drill out the two rivets on the left side (one above and one below the door hinge) |
| Step Three | Remove the rubber fuel door stops by gently twisting and pulling |
| Step Four | Loosen the plastic shroud by removing the two screws and plastic clip |
| Step Five | Remove the screws, nuts and washers from the adapter |
| Step Six | Mount the adapter into the holes the rubber door stops were in using supplied hardware and tighten |
| Step Seven | Reinstall the two bolts and plastic clip |
| Step Eight | Install the door by slipping the mounting studs into the holes made by drilling out the rivets then using supplied hardware and tighten |
| Step Nine | Install the last two bolts into the last two holes that remain |
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What You'll Learn
Drilling out the rivets
Next, remove the rubber fuel door stops by gently twisting and pulling. Loosen the plastic shroud by removing the two screws and the plastic clip and move it out of the way. This will allow room to tighten the nuts on the adapter.
Now, mount the adapter into the holes the rubber door stops were in using the supplied hardware and tighten. Then, reinstall the two bolts and plastic clip.
Finally, install the door by slipping the mounting studs into the holes made by drilling out the rivets, then using the supplied hardware and tighten. Install the last two bolts into the last two holes that remain.
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Removing the rubber fuel door stops
To remove the rubber fuel door stops on a 2005 Silverado, first open the original fuel door. Using a 1/4" drill bit, drill out the two rivets on the left side (one above and one below the door hinge). With the rivets gone, the fuel door will slide out. Remove the rubber fuel door stops by gently twisting and pulling.
To replace the fuel door, mount the adapter into the holes the rubber door stops were in using the supplied hardware and tighten. Reinstall the two bolts and plastic clip. Install the door by slipping the mounting studs into the holes made by drilling out the rivets, then tighten with the supplied hardware. Install the last two bolts into the last two holes that remain.
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Removing the plastic shroud
To remove the plastic shroud, you need to first loosen it by removing the two screws and the plastic clip. This will allow you to move it out of the way and give you room to tighten the nuts on the adapter.
The plastic shroud is attached to the fuel door, so you will need to remove the fuel door first. To do this, open the original fuel door and, using a 1/4" drill bit, drill out the two rivets on the left side (one above and one below the door hinge). Once the rivets are gone, the fuel door will slide right out. You can then remove the rubber fuel door stops by gently twisting and pulling.
Make sure you have a replacement fuel door ready to install before removing the old one, as this will ensure you do not lose any small parts.
Once the plastic shroud is loose, you can remove the screws, nuts, and washers from the adapter. This bracket bolts to where the rubber door stops went.
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Mounting the adapter
To mount the adapter, you'll need to use the holes where the rubber door stops were. Use the supplied hardware to tighten it into place, then reinstall the two bolts and plastic clip.
Now you can install the door. Slip the mounting studs into the holes you made by drilling out the rivets, then tighten using the supplied hardware. Install the last two bolts into the remaining two holes.
Before you mount the adapter, you'll need to remove the screws, nuts and washers from it. This bracket bolts to where the rubber door stops went. You'll also need to remove the rubber fuel door stops by gently twisting and pulling.
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Installing the new fuel door
To install the new fuel door, you will need to first open the original fuel door. Using a 1/4" drill bit, drill out the two rivets on the left side (one above and one below the door hinge). Once the rivets are gone, the fuel door will slide right out. Remove the rubber fuel door stops by gently twisting and pulling. Loosen the plastic shroud by removing the two screws and the plastic clip and move it out of the way. This will allow room to tighten the nuts on the adapter. Remove the screws, nuts and washers from the adapter. This bracket bolts to where the rubber door stops went. Mount the adapter into the holes the rubber door stops were in using the supplied hardware and tighten. Then reinstall the two bolts and plastic clip. Install the door by slipping the mounting studs into the holes made by drilling out the rivets then using supplied hardware and tighten. Install the last two bolts into the last two holes that remain.
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Frequently asked questions
Open the fuel door and use a 1/4" drill bit to drill out the two rivets on the left side. Once the rivets are gone, the fuel door will slide out.
Remove them by gently twisting and pulling, then mount the adapter into the holes they were in.
Loosen the plastic shroud by removing the two screws and the plastic clip. This will allow room to tighten the nuts.
