Envoy Conversion Step by Step

samandjen1 · 05-22-2003, 02:13 AM

This will be an on going thread until I am done with the Envoy Conversion on my 1998 Chevy S-10. I will start the conversion on 5/22/03 if the rain stops.I will provide pictures of everything to help others that will be doing this conversion. I want to start by listing all part numbers for the Envoy.If you plan on using the HID headlights See picture 1. If you plan on using the Sonoma Headlights with or with out the bulit in fog light see picture 2 and 3 for the cleared ones for the difference.If you shop around(Ebay,swap meets,etc) you will be able to find parts cheaper then buying new.

Envoy Front Cover 12377115
Front cover Chrome Molding 12377122 need Left and Right
Impact Bar 15045507
Spacer Front Cover 15016974 Order one of these there is a L/R in one package
Impact bar brace Right 15647600
Impact bar Brace Left 15647599

The Grille you can go with paintable or Chrome

Grille Assy Paintable one 12472678
Grille Assy Chrome 15015056
Grille Retainer Clips 15002520 Need 7
GMC Letters G-15634639 M-15634641 C-15634643

Headlights HID (I think only came on 2000 Model Envoy)PIC1
Complete Right Headlight assy with Balast 16526106
Complete Left Headlight assy with Balast 16526105
Headlights from a Sonoma or Jimmy PIC2
Complete Right Headlight assy w/ Fog Light built in 16526226
Complete Left Headlight assy w/ Fog Light built in 16526225

Headlights from a Sonoma or Jimmy PIC3 That have been cleared
Complete Right Headlight assy 16526228
Complete Left Headlight assy 16526227

Envoy Fog Lights
Fog Light Left and Right same part # 16513886 need 2
Fog Light Wiring Harness 12102664 need 2

I will add anything I come across while doing the install.
Hopefully the rain will stop.If it does I will post pictures on Friday.

samandjen1 · 05-22-2003, 11:30 PM

I had to down load and rename them.

Ok here we go
laying out parts and making sure I have everything ready

samandjen1 · 05-22-2003, 11:32 PM

Before shot

samandjen1 · 05-22-2003, 11:33 PM

First unhook the battery and wait 3 mintues(airbag battery has to drain)

Pull the two staps to remove the headlights L/R

samandjen1 · 05-22-2003, 11:37 PM

Pull the headlights out and mark wires where they go.

I left my lightbulbs in the S10 headlights until I was ready to install the sonoma headlights later.

samandjen1 · 05-22-2003, 11:39 PM

Next remove the turn signals L/R

Becarefull with the mounting tabs thay break easy.

samandjen1 · 05-22-2003, 11:41 PM

This is what the front end should look like with they headlights removed.

Move the headlight harnesses out of the way of the grille.

I flopped mine over the core support.

samandjen1 · 05-22-2003, 11:43 PM

Next the grille

It is held on by 11 clips. To remove it just pull on it slowly. It comes off very easy.I worked from the left to the right pulling a little at a time.

samandjen1 · 05-22-2003, 11:48 PM

I removed the bumper and valence as one piece.

6 bolts hold it on.

samandjen1 · 05-22-2003, 11:49 PM

everthing off

DarkCherryS10 · 05-22-2003, 11:50 PM

Are the bolts for the bumper and valence easy to find?

samandjen1 · 05-22-2003, 11:51 PM

yes 2 on top
2 inside bumper and 1 on each side bracket

samandjen1 · 05-22-2003, 11:56 PM

Sonoma impact bumper installed
Leave all bolts loose you you can adjust them later side to side and front to back.

samandjen1 · 05-22-2003, 11:57 PM

the S10 side bumper support brakets. Can't be used when doing this conversion.

Go to thread to see the right ones.

http://www.s10forum.com/forum/showth...y+p arts+came

here is a picture of the left on installed
Bolts loose also.

samandjen1 · 05-22-2003, 11:59 PM

here is a picture of the right one installed
Bolts loose also.

samandjen1 · 05-23-2003, 12:01 AM

test fitting the cover.

there is a rubber shroud that directs air to the raditor this needs to be trimmed for the bumper to fit.

samandjen1 · 05-23-2003, 12:03 AM

the cover slides on and there are 4 notches on the impact bar and a peg on each fender that hold it on. Also there are 2 holes on the inside to secure the bumper.

samandjen1 · 05-23-2003, 12:05 AM

next I test fit the grille. It snaps on in the same holes as the S10 grille but only uses 7 clips.

S10 had 11
2 on each side under headlights.
Sonoma grille is smaller so it doesn't use them.

samandjen1 · 05-23-2003, 12:09 AM

test fit headlights.

samandjen1 · 05-23-2003, 12:14 AM

now that everything looks good. Evenly spaced bumper left to right. I removed the headlights and grille again.

Now tighten all bolts.
Reinstall grille headlights with bulbs

Then I put the fog lights on.

DONE!

Took me about 2 1/2 hours
This is not hard to do. it is very east take off and put back on.
My final cost is right around $800 for all the parts.

samandjen1 · 05-23-2003, 12:15 AM

another picture

samandjen1 · 05-23-2003, 12:17 AM

Full side shot

The front looks higher than it really is this shot was taken after the truck was released off of the floorjack needs to be moved to settle back down.

gameloader · 05-23-2003, 01:21 AM

what about a diffrent radiator support?

samandjen1 · 05-23-2003, 01:24 AM

Quote:

Originally posted by gameloader
what about a diffrent radiator support?

Only need a different one if you have a 97 or older S10

98 + radiator cor support part# 15009394

samandjen1 · 05-27-2003, 08:30 AM

Quote:

Originally posted by 2kJimmy
Im in the middle of doing the bumper and i got the cover, the spacer(#6 in above pic) and the chorme pieces but i cant find were the spacer needs to go?

Spacer needs to be split in half left and right. One goes under each headlight it keeps the bumper from saging under the headlights.They just slip in.

samandjen1 · 05-27-2003, 12:45 PM

Quote:

Originally posted by dgb1891
Anyone know how this would look with the Xtreme ground effects?

go here

http://www.s10forum.com/forum/showth...envoy+x treme

samandjen1 · 05-29-2003, 10:25 PM

Quote:

Originally posted by LowDreamLT1
Also with the sonoma lights, do I buy all new bulbs and stuff for the lights?

same bulbs as s10 headlights 9005 and 9006 unless you go with HID

samandjen1 · 06-23-2003, 05:29 PM

Just added a new peice to the conversion
check it out

http://www.s10forum.com/forum/showth...s tep+by+step

samandjen1 · 06-25-2003, 01:00 PM

Quote:

Originally posted by samandjen1
Just added a new peice to the conversion
check it out

http://www.s10forum.com/forum/showth...s tep+by+step

Ok after hours of research and reading on HID's I found a very good company to buy from.

http://www.hids4less.com/www/index.asp

I will have my kit in 5 days, I will post all info and pics when it gets here.
The kit I bought is a stage 2 6000K. And they come with a 5 year warnnty on every part including the bulbs.Its inculdes 2 D2s Bulbs,ballasts,and all wiring for $650 + SHIPPING. As where GM wants $1200 for the factory 4300K light kit..

thebassn8tr · 07-17-2003, 07:49 PM

How do you get the foam padding to stay in place?

samandjen1 · 07-17-2003, 07:51 PM

Quote:

Originally posted by thebassn8tr
How do you get the foam padding to stay in place?

I just push it in under the headlights, stays there on its own.

samandjen1 · 08-03-2003, 09:22 PM

Quote:

Originally posted by MugenSi00
I have a 97 s10, do I need to change out the radiator support to do this converison? If so, to what?

Yes, to a 98 core support

rwhat · 04-06-2004, 10:05 PM

are the s10's wired for fog lights already? When i pulled the H/l out i could have sworn i saw a set of extra plugs. I was wondering about using the GM lights with the Fogs in them.

samandjen1 · 04-12-2004, 07:00 AM

Quote: Originally Posted by rwhat

are the s10's wired for fog lights already? When i pulled the H/l out i could have sworn i saw a set of extra plugs. I was wondering about using the GM lights with the Fogs in them.

yes already somewhat wired. If you have factory fogs installed you will be OK. If not then your body roll control computer will have to be reprogramed at GM.($200+) or just buy an aftermarket fog light wiring kit ($17)

sonomaguy · 06-24-2004, 11:09 PM

My questions are this, I have a 2003 Sonoma, I just want to put on the bumper cover, don't want the chrome corner pieces.
1. Do I need to disconnect the battery to put on the bumper cover? Will the airbags go off if I don't?
2. How do I unhook the old sonoma cover, remove and hook in the new one? Is this bolt on or pressure fit?

samandjen1 · 06-24-2004, 11:13 PM

Quote: Originally Posted by sonomaguy

My questions are this, I have a 2003 Sonoma, I just want to put on the bumper cover, don't want the chrome corner pieces.
1. Do I need to disconnect the battery to put on the bumper cover? Will the airbags go off if I don't?
2. How do I unhook the old sonoma cover, remove and hook in the new one? Is this bolt on or pressure fit?

1. Better safe than sorry. Unhook battery and wait 3-5 mintues.
2.There are 2 bolts in the center on the bumper cover. Lay on the ground and crawl under the bumper you can see them. Or remove your grill and look behind the bumper. then the cover snaps on to the impact bar.

05-22-2003, 02:13 AM	#1
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Envoy Conversion Step by Step This will be an on going thread until I am done with the Envoy Conversion on my 1998 Chevy S-10. I will start the conversion on 5/22/03 if the rain stops.I will provide pictures of everything to help others that will be doing this conversion. I want to start by listing all part numbers for the Envoy.If you plan on using the HID headlights See picture 1. If you plan on using the Sonoma Headlights with or with out the bulit in fog light see picture 2 and 3 for the cleared ones for the difference.If you shop around(Ebay,swap meets,etc) you will be able to find parts cheaper then buying new. Envoy Front Cover 12377115 Front cover Chrome Molding 12377122 need Left and Right Impact Bar 15045507 Spacer Front Cover 15016974 Order one of these there is a L/R in one package Impact bar brace Right 15647600 Impact bar Brace Left 15647599 The Grille you can go with paintable or Chrome Grille Assy Paintable one 12472678 Grille Assy Chrome 15015056 Grille Retainer Clips 15002520 Need 7 GMC Letters G-15634639 M-15634641 C-15634643 Headlights HID (I think only came on 2000 Model Envoy)PIC1 Complete Right Headlight assy with Balast 16526106 Complete Left Headlight assy with Balast 16526105 Headlights from a Sonoma or Jimmy PIC2 Complete Right Headlight assy w/ Fog Light built in 16526226 Complete Left Headlight assy w/ Fog Light built in 16526225 Headlights from a Sonoma or Jimmy PIC3 That have been cleared Complete Right Headlight assy 16526228 Complete Left Headlight assy 16526227 Envoy Fog Lights Fog Light Left and Right same part # 16513886 need 2 Fog Light Wiring Harness 12102664 need 2 I will add anything I come across while doing the install. Hopefully the rain will stop.If it does I will post pictures on Friday. Last edited by samandjen1 : 04-15-2005 at 11:39 PM.

04-06-2004, 10:05 PM	#33
rwhat Registered User Age: 30 Join Date: Mar 2003 Posts: 66 Location: Bay area User is: OffLine	Headlights/Fog are the s10's wired for fog lights already? When i pulled the H/l out i could have sworn i saw a set of extra plugs. I was wondering about using the GM lights with the Fogs in them.

04-12-2004, 07:00 AM	#34
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Re: Headlights/Fog Quote: Originally Posted by rwhat are the s10's wired for fog lights already? When i pulled the H/l out i could have sworn i saw a set of extra plugs. I was wondering about using the GM lights with the Fogs in them. yes already somewhat wired. If you have factory fogs installed you will be OK. If not then your body roll control computer will have to be reprogramed at GM.($200+) or just buy an aftermarket fog light wiring kit ($17)

06-24-2004, 11:09 PM	#35
sonomaguy Scoop Age: 48 Join Date: Apr 2003 Posts: 2,242 Location: Alberta,Canada User is: OffLine	Re: Envoy Conversion Step by Step My questions are this, I have a 2003 Sonoma, I just want to put on the bumper cover, don't want the chrome corner pieces. 1. Do I need to disconnect the battery to put on the bumper cover? Will the airbags go off if I don't? 2. How do I unhook the old sonoma cover, remove and hook in the new one? Is this bolt on or pressure fit?

06-24-2004, 11:13 PM	#36
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Re: Envoy Conversion Step by Step Quote: Originally Posted by sonomaguy My questions are this, I have a 2003 Sonoma, I just want to put on the bumper cover, don't want the chrome corner pieces. 1. Do I need to disconnect the battery to put on the bumper cover? Will the airbags go off if I don't? 2. How do I unhook the old sonoma cover, remove and hook in the new one? Is this bolt on or pressure fit? 1. Better safe than sorry. Unhook battery and wait 3-5 mintues. 2.There are 2 bolts in the center on the bumper cover. Lay on the ground and crawl under the bumper you can see them. Or remove your grill and look behind the bumper. then the cover snaps on to the impact bar.

05-22-2003, 11:33 PM	#4
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	First unhook the battery and wait 3 mintues(airbag battery has to drain) Pull the two staps to remove the headlights L/R

05-22-2003, 11:37 PM	#5
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Pull the headlights out and mark wires where they go. I left my lightbulbs in the S10 headlights until I was ready to install the sonoma headlights later.

05-22-2003, 11:39 PM	#6
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Next remove the turn signals L/R Becarefull with the mounting tabs thay break easy.

05-22-2003, 11:50 PM	#11
DarkCherryS10 Registered User Age: 26 Join Date: Feb 2002 Posts: 2,220 Location: Maryland User is: OffLine	Are the bolts for the bumper and valence easy to find?

05-22-2003, 11:51 PM	#12
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	yes 2 on top 2 inside bumper and 1 on each side bracket

05-23-2003, 12:03 AM	#17
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	the cover slides on and there are 4 notches on the impact bar and a peg on each fender that hold it on. Also there are 2 holes on the inside to secure the bumper.

05-23-2003, 01:21 AM	#23
gameloader wOrk iN PrOGreSS Age: 25 Join Date: Jan 2003 Posts: 2,244 Location: Covina Ca User is: OffLine	what about a diffrent radiator support?

05-23-2003, 01:24 AM	#24
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by gameloader what about a diffrent radiator support? Only need a different one if you have a 97 or older S10 98 + radiator cor support part# 15009394

05-27-2003, 08:30 AM	#25
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by 2kJimmy Im in the middle of doing the bumper and i got the cover, the spacer(#6 in above pic) and the chorme pieces but i cant find were the spacer needs to go? Spacer needs to be split in half left and right. One goes under each headlight it keeps the bumper from saging under the headlights.They just slip in.

05-27-2003, 12:45 PM	#26
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by dgb1891 Anyone know how this would look with the Xtreme ground effects? go here http://www.s10forum.com/forum/showth...envoy+x treme

05-29-2003, 10:25 PM	#27
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by LowDreamLT1 Also with the sonoma lights, do I buy all new bulbs and stuff for the lights? same bulbs as s10 headlights 9005 and 9006 unless you go with HID

06-23-2003, 05:29 PM	#28
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Just added a new peice to the conversion check it out http://www.s10forum.com/forum/showth...s tep+by+step

06-25-2003, 01:00 PM	#29
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by samandjen1 Just added a new peice to the conversion check it out http://www.s10forum.com/forum/showth...s tep+by+step Ok after hours of research and reading on HID's I found a very good company to buy from. http://www.hids4less.com/www/index.asp I will have my kit in 5 days, I will post all info and pics when it gets here. The kit I bought is a stage 2 6000K. And they come with a 5 year warnnty on every part including the bulbs.Its inculdes 2 D2s Bulbs,ballasts,and all wiring for $650 + SHIPPING. As where GM wants $1200 for the factory 4300K light kit..

07-17-2003, 07:49 PM	#30
thebassn8tr Registered User Age: 27 Join Date: Feb 2003 Posts: 2,092 Location: Poway/San Diego User is: OffLine	How do you get the foam padding to stay in place?

07-17-2003, 07:51 PM	#31
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by thebassn8tr How do you get the foam padding to stay in place? I just push it in under the headlights, stays there on its own.

08-03-2003, 09:22 PM	#32
samandjen1 Ford Lightning Owner Age: 37 Join Date: Mar 2003 Posts: 5,865 Location: South Jersey User is: OffLine	Quote: Originally posted by MugenSi00 I have a 97 s10, do I need to change out the radiator support to do this converison? If so, to what? Yes, to a 98 core support

LinkBacks (?) LinkBack to this Thread: http://www.s10forum.com/forum/f199/envoy-conversion-step-by-step-178762/
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