GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Blazer - 4WD - RHD 🢒 Body and Accessories 🢒 Body Front End 🢒 Front Bumper Impact Bar Replacement

Removal Procedure

    Object Number: 604526 Size: SH
  1. Remove the radiator grille. Refer to Grille Replacement in Exterior Trim.
  2. Remove the radiator air intake baffle. Refer to Air Intake Baffle Replacement - Radiator .
  3. Disconnect the headlamp washer filler hose from the washer solvent container.
  4. Disconnect the electrical connector to the headlamp washer assembly.
  5. Remove the nut and the bolt that retain the brace to the bumper impact bar.
  6. Remove the fog lamp connectors, if equipped. Refer to Front Parking and Turn Signal and Fog Lamp Assembly Replacement in Lighting Systems.
  7. Remove the nuts and the bolts that retain the bumper impact bar to the frame.
  8. Remove the bumper impact bar from the vehicle.
  9. If replacing the bumper impact bar, perform the following:
    10. 9.1. Remove the headlamp washer container from the bumper impact bar. Refer to Headlamp Washer Solvent Container Replacement in Wipers/Washer Systems.
    9.2. Remove the license plate bracket, if equipped. Refer to Front License Plate Bracket Replacement .
    9.3. Remove the headlamp washer nozzle from the bumper impact bar. Refer to Headlamp Washer Nozzle Assembly Replacement in Wipers/Washer Systems.
    9.4. Remove the air deflector from the bumper impact bar. Refer to Front Bumper Fascia Air Deflector Replacement .

Installation Procedure

    Object Number: 604526 Size: SH
  1. Install the following components if removed:
    2. 1.1. Install the air deflector to the bumper impact bar. Refer to Front Bumper Fascia Air Deflector Replacement .
    1.2. Install the headlamp washer container to the bumper impact bar. Refer to Headlamp Washer Solvent Container Replacement in Wipers/Washer Systems.
    1.3. Install the headlamp washer nozzle to the bumper impact bar. Refer to Headlamp Washer Nozzle Assembly Replacement in Wipers/Washer Systems.
    1.4. Install the license plate bracket. Refer to Front License Plate Bracket Replacement .
  2. Install the bumper impact bar to the vehicle.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the bolts and the nuts that retain the bumper impact bar to the frame.

    4. Tighten
    Tighten the bumper impact bar to the frame bolts to 40 N·m (30 lb ft).

  4. Install the nuts and the bolts that retain the bumper impact bar to the brace.

    5. Tighten
    Tighten the bumper impact bar to the brace bolts to 40 N·m (30 lb ft).

  5. Install the fog lamp connectors, if equipped. Refer to Front Parking and Turn Signal and Fog Lamp Assembly Replacement in Lighting Systems.
  6. Connect the electrical connector to the headlamp washer assembly.
  7. Connect the headlamp washer filler hose to the washer solvent container.
  8. Install the radiator air intake baffle. Refer to Air Intake Baffle Replacement - Radiator .
  9. Install the radiator grille. Refer to Grille Replacement in Exterior Trim.