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Envoy Conversion Step by Step


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Old 05-22-2003, 01:13 AM   2 links from elsewhere to this Post. Click to view. #1
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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.
  1. Envoy Front Cover 12377115
  2. Front cover Chrome Molding 12377122 need Left and Right
  3. Impact Bar 15045507
  4. Spacer Front Cover 15016974 Order one of these there is a L/R in one package
  5. Impact bar brace Right 15647600
  6. Impact bar Brace Left 15647599
The Grille you can go with paintable or Chrome
  1. Grille Assy Paintable one 12472678
  2. Grille Assy Chrome 15015056
  3. Grille Retainer Clips 15002520 Need 7
  4. 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 10:39 PM.
Old 05-22-2003, 10:30 PM   #2
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I had to down load and rename them.


Ok here we go
laying out parts and making sure I have everything ready
Attached Images
File Type: jpg getting ready.jpg (52.4 KB, 4860 views)
Old 05-22-2003, 10:32 PM   #3
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Before shot
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File Type: jpg before.jpg (57.5 KB, 3615 views)
Old 05-22-2003, 10:33 PM   #4
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First unhook the battery and wait 3 mintues(airbag battery has to drain)

Pull the two staps to remove the headlights L/R
Old 05-22-2003, 10:37 PM   #5
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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.
Old 05-22-2003, 10:39 PM   #6
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Next remove the turn signals L/R

Becarefull with the mounting tabs thay break easy.
Old 05-22-2003, 10:41 PM   #7
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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.
Attached Images
File Type: jpg no lights.jpg (61.5 KB, 3656 views)
Old 05-22-2003, 10:43 PM   #8
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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.
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File Type: jpg pulled grille.jpg (70.0 KB, 2833 views)
Old 05-22-2003, 10:48 PM   #9
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I removed the bumper and valence as one piece.

6 bolts hold it on.
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File Type: jpg side shot.jpg (54.8 KB, 2810 views)
Old 05-22-2003, 10:49 PM   #10
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everthing off
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File Type: jpg stripped.jpg (77.1 KB, 3469 views)
Old 05-22-2003, 10:50 PM   #11
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Are the bolts for the bumper and valence easy to find?
Old 05-22-2003, 10:51 PM   #12
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yes 2 on top
2 inside bumper and 1 on each side bracket
Old 05-22-2003, 10:56 PM   #13
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Sonoma impact bumper installed
Leave all bolts loose you you can adjust them later side to side and front to back.
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File Type: jpg impact.jpg (74.5 KB, 3833 views)
Old 05-22-2003, 10:57 PM   #14
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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.
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File Type: jpg left.jpg (52.5 KB, 3234 views)
Old 05-22-2003, 10:59 PM   #15
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here is a picture of the right one installed
Bolts loose also.
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File Type: jpg right.jpg (46.7 KB, 2416 views)
Old 05-22-2003, 11:01 PM   #16
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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.
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File Type: jpg test cover.jpg (69.8 KB, 3700 views)
Old 05-22-2003, 11:03 PM   #17
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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.
Old 05-22-2003, 11:05 PM   #18
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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.
Attached Images
File Type: jpg grill test.jpg (68.6 KB, 3657 views)
Old 05-22-2003, 11:09 PM   #19
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test fit headlights.
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File Type: jpg hl test side.jpg (59.7 KB, 3963 views)
Old 05-22-2003, 11:14 PM   #20
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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.
Attached Images
File Type: jpg done fog.jpg (63.7 KB, 3205 views)
Old 05-22-2003, 11:15 PM   #21
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another picture
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File Type: jpg fog.jpg (59.3 KB, 2869 views)
Old 05-22-2003, 11:17 PM   #22
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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.
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File Type: jpg full side.jpg (61.4 KB, 3354 views)
Old 05-23-2003, 12:21 AM   #23
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what about a diffrent radiator support?
Old 05-23-2003, 12:24 AM   #24
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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
Old 05-27-2003, 07:30 AM   #25
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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.
Old 05-27-2003, 11:45 AM   #26
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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
Old 05-29-2003, 09:25 PM   #27
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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
Old 06-23-2003, 04:29 PM   #28
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Just added a new peice to the conversion
check it out

http://www.s10forum.com/forum/showth...s tep+by+step
Old 06-25-2003, 12:00 PM   #29
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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..
Old 07-17-2003, 06:49 PM   #30
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How do you get the foam padding to stay in place?
Old 07-17-2003, 06:51 PM   #31
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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.
Old 08-03-2003, 08:22 PM   #32
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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
Old 04-06-2004, 09:05 PM   #33
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rwhat
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.
Old 04-12-2004, 06:00 AM   #