Bumper System Chevrolet Chevy Express H2500

Specifications

Fastener Tightening Specifications

Scheme 152

1. Remove the bolts that retain the front license plate bracket to the bumper.
2. Remove the front license plate bracket from the bumper.

Scheme 153

1. Install the front license plate bracket to the bumper. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the front license plate bracket retaining bolts to the bumper. Tighten Tighten the front license plate bracket retaining bolts to 3 N.m (27 lb in).

Scheme 154

1. Using pliers, gently squeeze the retainer tabs to release the air deflector (2) from the front bumper (1).
2. Remove the air deflector (2) from the front bumper (1).

Scheme 155

1. Install the air deflector (2) to the front bumper (1).
2. Install and fully seat the retainer tabs that retain the air deflector (2) to the front bumper (1).

Scheme 156

1. Release the push-pins that retain the air deflector (2) to the front impact bar (1).
2. Remove the air deflector (2) from the front impact bar (1).

Scheme 157

1. Install the air deflector (2) to the front impact bar (1).
2. Install and fully seat the push-pins that retain the air deflector (2) to the front impact bar (1).

Fascia Replacement - Front Bumper (Luxury Y91)

Tools Required

1. J 25070 Heat Gun
2. 3M 07502 3M Scotch Brite Adhesive and Stripe Removal Disc

Removal Procedure

1. Remove the front grille from the vehicle. Refer to «GRILLE REPLACEMENT (UPLEVEL)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exteriorinterior-trim/#exterior-trim) or «GRILLE REPLACEMENT (BASE)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exteriorinterior-trim/#exterior-trim) .
2. Remove the bolts that retain the front fascia (4) to the mounting bracket (3).
3. Remove the push pin retainers (1) from the top of the front fascia.
4. Remove the front fascia support using pliers. Gently press on the retaining tabs on the fascia support, if required.
5. Remove the bolts that retain the front fascia mounting brackets to the bumper, if required.

Installation Procedure

Scheme 158

1. Install the bolts that retain the front fascia mounting brackets to the bumper, if removed. Tighten Tighten the front fascia mounting bracket to bumper bolts to 2 N.m (18 lb in).
2. Install the front fascia support (2) to the bumper, if removed. Tap down on the support with a rubber mallet, in order to install the tabs into the bumper.
3. Install the push pin retainers (1) to the top of the front fascia.
4. Install the bolts that retain the front fascia (4) to the mounting bracket (3). Tighten Tighten the front fascia to mounting bracket bolts to 2 N.m (18 lb in).
5. Install the front grille to the vehicle. Refer to «GRILLE REPLACEMENT (UPLEVEL)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exteriorinterior-trim/#exterior-trim) or «GRILLE REPLACEMENT (BASE)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exteriorinterior-trim/#exterior-trim) .

Scheme 159

1. Remove the front bumper from the vehicle. Refer to «Bumper Replacement - Front»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
2. Using pliers, gently squeeze the retainer tabs on the molding. Push the retainer tabs through the slots in the bumper.
3. Remove the front bumper step pad (1) from the bumper.

Scheme 160

1. Align the retainer tabs on the front bumper step pad (1) with the slots in the bumper.
2. Using a rubber mallet, set the retainer tabs in place starting at the center of the front bumper step pad and work toward each end of the pad.
3. Install the front bumper to the vehicle. Refer to «Bumper Replacement - Front»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .

Scheme 161

1. Mark the location of the fasteners and the brackets to the bumper.
2. Remove the front bumper bracket. Refer to «Bracket Replacement - Front Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
3. Remove the bolts retaining the bumper to the frame.
4. Remove the front bumper from the vehicle.
5. Remove the step pad from the front bumper. Refer to «Step Pad Replacement - Front Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
6. Remove the air deflector from the front bumper. Refer to «Air Deflector Replacement - Front Bumper Fascia (Light Duty)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) or «Air Deflector Replacement - Front Bumper Fascia (Heavy Duty)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .

Scheme 162

1. Install the air deflector to the front bumper. Refer to «Air Deflector Replacement - Front Bumper Fascia (Light Duty)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) or «Air Deflector Replacement - Front Bumper Fascia (Heavy Duty)»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
2. Install the step pad to the front bumper. Refer to «Step Pad Replacement - Front Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
3. Install the front bumper to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the bolts that retain the front bumper to the frame. Tighten Tighten the bolts to 50 N.m (37 lb ft).

Scheme 163

1. Remove the bolts that retain the bracket (2) to the bumper (1).
2. Remove the bracket (2) from the bumper (1).

Scheme 164

1. Install the bracket (2) to the bumper (1). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the bolts that retain the bracket (2) to the bumper (1). Tighten Tighten the bumper bracket retaining bolts to 25 N.m (18 lb ft).

Scheme 165

1. Remove the rear step pad from the vehicle. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
2. Remove the bolts that attach the rear bumper fascia (1) to the impact bar (2).
3. Remove the rear bumper fascia from the vehicle.
4. Remove the bolts that attach the rear bumper fascia impact bar to the vehicle, if required.

Scheme 166

1. Install the bolts that attach the rear bumper fascia impact bar to the vehicle if removed.
2. Install the rear bumper fascia to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
3. Install the bolts that attach the rear bumper fascia (1) to the impact bar (2). Tighten Tighten the mounting bracket bolts to 2 N.m (18 lb in).
4. Install the rear step pad from the vehicle. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .

Scheme 167

1. Remove the nuts (3) that retain the step pad extension to the bumper.
2. Remove the step pad extension (2) from the bumper (4).

Scheme 168

1. Install the step pad extension (2) to the bumper (4). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the step pad extension retaining nuts (3) to the bumper. Tighten Tighten the step pad extension nuts to 1.5 N.m (13 lb in).

Scheme 169

1. Using pliers, gently squeeze the tangs of the step pad. Push the tangs through the slots in the bumper.
2. Remove the step pad (1) from the bumper (4).

Scheme 170

1. Install the step pad (1) on the bumper (4).
2. Align the tangs on the step pad with the slots in the bumper.
3. Using a rubber mallet, set the tangs in place starting at the center of the step pad and work toward each end of the pad.

1. Raise and support the vehicle with suitable safety stands.
2. Remove the rear bumper step pad from the bumper. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
3. Remove the rear bumper from the vehicle. Refer to «Bumper Replacement - Rear»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
4. Mark the location of the inner bumper brace to the bumper.
5. Remove the nuts (8) that retain the outer bumper brace (1) to the frame.
6. Remove the nuts and the bolts (6) that retain the outer bumper brace to the bumper.
7. Remove the bolts (10) that retain the inner bumper brace (2) to the bumper.
8. Remove the outer (1) then the inner (2) bumper brace from the frame and the bumper.

Scheme 171

1. Install the outer (1) then the inner (2) bumper brace to the frame and bumper.
2. Align the inner bumper brace with the marks made prior to removal. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
3. Install the inner bumper brace retaining bolts to the bumper. Tighten Tighten the inner bumper brace retaining bolts to 25 N.m (18 lb ft).
4. Install the outer bumper brace retaining nuts and bolts (6) to the bumper. Tighten Tighten the outer bumper brace retaining nuts and bolts to 50 N.m (37 lb ft).
5. Install the outer bumper brace nuts (8) and stud plate (7) to the frame. Tighten Tighten the outer bumper brace nuts to 50 N.m (37 lb ft).
6. Install the rear bumper to the vehicle. Refer to «Bumper Replacement - Rear»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
7. Install the rear bumper step pad to the bumper. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
8. Lower the vehicle.

Scheme 172

1. Mark the location of the braces and the fasteners.
2. Remove the nuts (1) that retain the rear bumper outer and inner braces to the frame.
3. Remove the bumper (3) from the vehicle.
4. Remove the rear bumper braces from the bumper. Refer to «Bracket Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
5. Remove the rear bumper step pad from the bumper. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
6. Remove the rear bumper step pad extensions from the bumper, if equipped. Refer to «Step Pad Extension Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .

Scheme 173

1. Install the rear bumper step pad to the bumper. Refer to «Step Pad Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
2. Install the rear bumper step pad extensions to the bumper. Refer to «Step Pad Extension Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
3. Install the rear bumper braces to the bumper. Refer to «Bracket Replacement - Rear Bumper»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#bumper-system) .
4. Install the bumper (3) to the vehicle. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
5. Install the inner and outer bumper impact bar brace retaining nuts (1) to the frame. Tighten Tighten the inner and outer bumper impact bar brace retaining nuts to 50 N.m (37 lb ft).

Scheme 174

See also:
• FASTENER NOTICE
• GRILLE REPLACEMENT (UPLEVEL)
• Bumper Replacement - Front