SECTION 11A - TT ZAFIRA BODY STYLING KIT

1. GENERAL DESCRIPTION

2. SERVICE OPERATIONS

2.1 FRONT SPOILER

REMOVE

REINSTALL

2.2 ROCKER PANEL SKIRT

REMOVE

REINSTALL

2.3 REAR SIDE EXTENSION

REMOVE

REINSTALL

2.4 REAR SPOILER

REMOVE

REINSTALL

2.5 IDENTIFICATION PLATE, LABELS & BADGE

IDENTIFICATION PLATE

REAR DOOR LABELS

LIFTGATE BADGE

1. GENERAL DESCRIPTION

This Service Manual Supplement describes the service procedures for the Holden By Design body styling kit

available for TT Zafira vehicles. The body kit consists of the following major components, which are painted the

vehicle’s body colour.

• Front spoiler, attached to the front bumper fascia,

• Rocker panel skirts, fitted along each side of the vehicle,

• Rear side extensions, fitted to each side of the rear bumper fascia, and

• Rear spoiler, attached to the liftgate.

All of the com ponents are attached to the vehic le with urethane adhesive. In addition, the fr ont spoiler, r ock er panel

skirts and rear side extensions are also secured to the vehicle with several retainers and/or screws. The front and

rear spoilers are also attached with pressure sensitive double-sided tape.

Replacement body kit com ponents are supplied in a kit that also includes the attaching parts, adhesive and where

required, double-sided tape. Both the left-hand and right-hand rear side extensions are supplied in the one kit. Refer

to Figure 11A-1 for the contents of each kit.

The front spoiler, rocker panel skirts and rear side extensions are made from polyurethane (PUR), while the rear

spoiler is made from ABS plastic. Replacement parts are supplied primed and will require final finishing before

painting. Many different types and brands of paint are available for refinishing the body kit components and while

the painting procedures are relatively straight forward, the correct steps must be followed. Refer to your paint

manufacturer or supplier for further information if required.

The HBD Zafira Body Styling Kit also includes unique alloy wheels. A HBD identification plate and HBD labels are

also included.

Figure 11A-1

Legend

1. Front Spoiler Side Retainer (x 2) 12. Rear Side Extension Retaining Screw (x 2)

2. Front Spoiler Lower Retainer (x 2) 13. Rear Side Extension

3. Front Spoiler 14. Rear Side Extension Urethane Adhesive Kit

4. Front Spoiler Pressure Sensitive Double Side Tape 15. Rear Spoiler

5. Front Spoiler Urethane Adhesive Kit 16. Antenna Boss (x 2)

6. Rocker Panel Skirt Front Retainer 17. Rear Spoiler Pressure Sensitive Double Side Tape

7. Rocker Panel Skirt Urethane Adhesive Kit 18. Rear Spoiler Urethane Adhesive Kit

8. Rocker Panel Skirt Retaining Screw (x 3) 19. Rear Door Holden By Design Label (x 2)

9. Rocker Panel Skirt Retaining Screw Washer (x 3) 20. Liftgate Holden By Design Badge

10. Rocker Panel Skirt Retainer (x 3) 21. Holden By Design Identification Plate

11. Rocker Panel Skirt 22. Alloy Wheel (x 4)

NOTE: Replacement kits containing the parts shown are available for the front spoiler, left-hand or right-hand rocker panel

skirt (one kit each), both left-hand and right-hand rear side extensions (together in one kit) and the rear spoiler.

2. SERVICE OPERATIONS

2.1 FRONT SPOILER

REMOVE

1. From underneath each side of the front bumper

fascia, remove the retainer (1) attaching the front

spoiler to the fascia.

2. From eac h s ide of the f ront bumper fasc ia, rem ove

the retainer (2) attaching the front spoiler to the

fascia.

Figure 11A-2

3. Beginning at one end of the spoiler and using a

sharp knife, cut the urethane adhesive bead and

double- sided tape (1) between the spoiler and

bumper fascia in the area shown, work ing towards

the centre.

NOTE: Hold outward pressure on the spoiler to assist

breaking the bead.

NOTE: Piano wire may be a useful alternative to a

knife.

4. Repeat for the opposite side and remove the

spoiler.

5. If the spoiler and / or bumper fascia are to be

reused, remove the double-sided tape and any

residual tape adhesive. Also remove most of the

urethane bead with a knife to provide a smooth,

sound surface. It is not necessary to completely

remove it.

Figure 11A-3

REINSTALL

The front spoiler is supplied primed and is to be

painted in the vehicle’s body colour.

IMPORTANT: The adhesive track (1 and 2) must be

masked prior to the application of primer or topcoat,

refer to Figure 11A-4.

Figure 11A-4

The vehicle paint colour code (1) can be found on the

identification label which is attached to the right-hand

centre pillar.

While the painting procedures are relatively straight

forward, the correct steps must be followed for

refinishing PUR (polyurethane). Refer to your paint

manufacturer for further information as required.

1. Remove the m ask ing tape f rom the adhesive tr ack

on the rear of the spoiler.

2. If required, remove any residual paint from the

adhesive track with 80# sandpaper.

Figure 11A-5

3. If a new bumper fascia has been fitted, seat the

spoiler in position with the aid of an assistant and

mark the two lower and two side retainer holes.

4. Remove the spoiler and drill two 6 mm holes in the

bumper fascia for the lower retainers.

5. Drill a 5 mm hole for each side retainer hole.

6. Clean the bonding surfaces of the bumper fascia

and spoiler with Prepsol or equivalent and dry

thoroughly with a clean, dry cloth to remove any

residue.

7. Apply five lengths of the 3M Pressure Sensitive

Tape supplied with the package, or equivalent, to

the rear of the spoiler in the pos itions shown (1) to

the lower part of the adhesive track and (2) to the

underside of the upper lip, refer to Figure 11A-7.

NOTE: When applying the tape to the glue track (1),

allow enough space for a bead of urethane to be

applied above.

Figure 11A-6

Figure 11A-7

8. Immediately before applying the urethane adhesive, clean the surfaces with Betaclean 3350 supplied with

the replacement kit, or equivalent.

IMPORTANT: T he following steps m ust be completed within 15 m inutes. Carefully read the directions provided

with the urethane adhesive prior to opening the package.

9. Using a circ ular motion, apply a bead of Betalink K1 urethane adhesive (1) supplied with the replacement k it,

or equivalent, into the glue track (1) above the double sided tape, and along the along the underside of the

upper lip (2), in three places, refer to Figure 11A-8.

Figure 11A-8

10. W ith the aid of an assistant, f it the spoiler caref ully

onto the bumper facia.

11. Press the spoiler onto the fascia and apply

masking tape (1) as required across the spoiler

and fascia to temporarily fix the spoiler in position.

NOTE: The use of foam blocks or cardboard packing

(2) will greatly assist in secur ing edges of the s poiler in

position against the fascia until the urethane cures.

Figure 11A-9

12. Reinstall the lower (1) and side (2) retainers, one

place each side.

13. Immediately clean of any excess adhesive as

required using a spatula and the Betaclean 3350

supplied with the replacement kit, or equivalent.

14. Allow a m inim um of over night curing or as directed

on the instructions provided with the urethane

adhesive.

15. Once cured, remove the tape and packing.

Figure 11A-10

2.2 ROCKER P ANEL SKIRT

REMOVE

1. Open the doors and remove the lower door seal.

2. Remove the screw (1) and washer (2) and prise

the retainer (3) from the underside of the rocker

panel skirt, three places.

Figure 11A-11

3. Remove the retainer (1) attaching the front of the

skirt to the fender liner.

Figure 11A-12

4. Begin at the front of the skirt and using a sharp

knif e, cut the urethane adhesive bead ( 1) between

the skirt and body.

NOTE: Hold outward pressure on the skirt to assist

breaking the bead.

5. Continue cutting along the entire length of the skirt.

6. Cut the adhesive from the areas adjacent to each

retainer hole (2).

7. Remove the skirt from the vehicle.

8. If the skirt is to be reused, remove most of the

urethane bead with a knife to provide a smooth,

sound surface. It is not necessary to completely

remove it.

Figure 11A-13

REINSTALL

The rocker panel skirt is supplied primed and is to be painted in the vehicle’s body colour.

IMPORTANT: The adhesive track (1) and areas around the three m ounting holes (2) must be masked prior to

the application of primer or topcoat, refer to Figure 11A-14.

Figure 11A-14

The vehicle paint colour code (1) can be found on the

identification label which is attached to the right-hand

centre pillar.

While the painting procedures are relatively straight

forward, the correct steps must be followed for

refinishing PUR (polyurethane). Refer to your paint

manufacturer for further information as required.

1. Remove the m ask ing tape f rom the adhesive tr ack

on the rear of the skirt.

2. If required, remove any residual paint from the

adhesive track with 80# sandpaper.

3. Clean the bonding surfaces of the rocker panel

and skirt with Prepsol or equivalent and dry

thoroughly with a clean, dry cloth to remove any

residue.

4. Immediately before applying the adhesive, clean

the surf aces with the Betaclean 3350 supplied with

the replacement kit, or equivalent.

Figure 11A-15

IMPORTANT: The following steps must be completed

within 15 minutes. Carefully read the directions

provided with the urethane adhesive prior to opening

the package.

5. Using a circular motion, apply a bead of Betalink

K1 urethane adhesive supplied with the

replacement kit, or equivalent, each side of the

three retainer holes (1) and along the glue track

(2).

Figure 11A-16

6. With the aid of an assistant, fit the skirt carefully

onto the vehicle.

7. Reinstall the retainer (1) into the hole on the

underside of the skirt, three places.

8. Install the screw (2) and washer (3) into each

retainer and tighten the screw securely.

Figure 11A-17

9. Open the doors and press the upper edge of the

sk irt onto the r ock er panel and apply mask ing tape

(1) across the skirt and sill to temporarily fix it in

position.

10. Wedge foam blocks or cardboard packing (2)

between the doors and sk irt to maintain downward

pressure on the skirt while the urethane adhesive

cures.

Figure 11A-18

11. If required, drill a 5 m m hole through the front skir t

hole into the fender liner.

12. Insert the retainer (1).

13. Clean of any excess adhesive as required using a

spatula and Betaclean 3350 supplied with the

replacement kit, or equivalent.

14. Allow a m inim um of over night curing or as directed

on the instructions provided with the urethane

adhesive.

15. Once cured, remove the tape and reinstall the

lower door seal.

Figure 11A-19

2.3 REAR SIDE EXTENSION

REMOVE

1. Remove the two screws (1) attac hing the rear side

extension (2) to the rear bumper fascia.

Figure 11A-20

2. Begin at the lower rear of the side extension and

using a sharp knife, cut the urethane adhesive

bead (1) between the side extension and bumper

fascia.

NOTE: Hold outward press ure on the s ide extens ion to

assist breaking the bead.

3. Remove the side extension from the vehicle.

4. If the side extension is to be r eused, remove m ost

of the urethane bead with a knife to provide a

smooth, sound surface. It is not necessary to

completely remove it.

Figure 11A-21

REINSTALL

The r ear s ide extens ion is s upplied primed and is to be

painted in the vehicle’s body colour.

IMPORTANT: T he adhesive trac k ( 1) m ust be mask ed

prior to the application of primer or topcoat.

Figure 11A-22

The vehicle paint colour code (1) can be found on the

identification label which is attached to the right-hand

centre pillar.

NOTE: While the painting procedures are relatively

straight f orward, the correc t steps m ust be followed for

refinishing PUR (polyurethane). Refer to your paint

manufacturer for further information as required.

1. Rem o ve the m ask ing tape fr om the adhesive trac k

on the rear of the side extension.

2. If required, remove any residual paint from the

adhesive track with 80# sandpaper.

Figure 11A-23

3. If the rear bumper fascia has been replaced,

temporarily fit the rear side extension in position

and mar k the two attaching scr ew holes in the rear

bumper fascia.

4. Remove the side extension and drill a 3 mm hole

at each mark.

5. Clean the bonding surfaces of the rear bumper

fascia and side extension with Prepsol or

equivalent and dry thoroughly with a clean, dry

cloth to remove any residue.

6. Immediately before applying the adhesive, clean

the surf aces with the Betaclean 3350 supplied with

the replacement kit, or equivalent.

Figure 11A-24

IMPORTANT: The following steps must be completed

within 15 minutes. Carefully read the directions

provided with the urethane adhesive prior to opening

the package.

7. Using a circular motion, apply a bead of Betalink

K1 urethane adhesive (1) supplied with the

replacement kit, or equivalent, along the track on

the back of the side extension as shown.

Figure 11A-25

8. Fit the side extension carefully onto the vehicle.

9. Press the upper edge of the side extension onto

the rear bum per f asc ia and apply mas k ing tape (1)

across the side extension to temporarily fix it in

position.

NOTE: The use of foam blocks or cardboard packing

(2) will greatly assist in securing edges of the

extension in position against the fascia until the

urethane cures.

Figure 11A-26

10. Install the two screws (1) attaching the side

extension (2) to the bumper fascia and tighten

securely.

11. Clean of any excess adhesive as required using a

spatula and Betaclean 3350 supplied with the

replacement kit, or equivalent.

12. Allow a m inim um of over night curing or as directed

on the instructions provided with the urethane

adhesive.

13. Once cured, remove the tape.

Figure 11A-27

2.4 REAR SPOILER

REMOVE

1. Beginning at one end of the spoiler, use a length of

piano wire to carefully cut the urethane adhesive

and double-sided tape from the perimeter of the

spoiler attaching surface. Move the wire in a

cutting motion back and forth as shown.

2. Remove the spoiler.

3. If the spoiler is to be reused, remove the double-

sided tape and clean off any remaining adhesive.

Also remove most of the urethane bead with a

knife to provide a smooth, sound surface. It is not

necessary to completely remove it.

Figure 11A-28

REINSTALL

The rear spoiler is supplied primed and is to be painted

in the vehicle’s body colour.

IMPORTANT: T he adhesive area (1) m ust be mask ed

prior to the application of primer or topcoat.

Figure 11A-29

The vehicle paint colour code (1) can be found on the

identification label which is attached to the right-hand

centre pillar.

While the painting procedures are relatively straight

forward, the correct steps must be followed for

refinishing ABS plastic. Refer to your paint

manufacturer for further information as required.

1. Clean the bonding surfaces of the liftgate and

spoiler with Prepsol or equivalent and dry

thoroughly with a clean, dry cloth to remove and

residue.

Figure 11A-30

2. Apply two lengths of the 3M Pressure Sensitive

Tape (1 & 2) supplied with the replacement kit, or

equivalent, onto each side of the spoiler.

3. Immediately before applying the adhesive, clean

the surf aces with the Betaclean 3350 supplied with

the replacement kit, or equivalent.

Figure 11A-31

IMPORTANT: The following steps must be completed

within 15 minutes. Carefully read the directions

provided with the urethane adhesive prior to opening

the package.

4. Using a circular motion, apply a bead of Betalink

K1 urethane adhesive (1) supplied with the

replacement kit, or equivalent, along the area

shown.

5. Remove the backing paper from the double-sided

tape and with the aid of an assistant, fit the spoiler

carefully onto the liftgate.

Figure 11A-32

6. Press the spoiler firmly into position to ensure a

positive bond of the double-sided tape.

7. Apply masking tape across the spoiler to

temporarily fix it in position.

NOTE: The use of foam blocks or cardboard packing

will greatly assist in s ec ur ing the edges of the spoiler in

position until the urethane cures.

8. Clean of any excess adhesive as required using a

spatula and Betaclean 3350 supplied with the

replacement kit, or equivalent.

9. Allow a m inim um of overnight curing or as directed

on the instructions provided with the urethane

adhesive.

10. Once cured, remove the tape.

11. Carefully open the liftgate and ensure the spoiler

clears the radio antenna.

12. If required, install the antenna boss (1), between

the antenna mast and base. Ensure the boss is

seated correctly and tightened securely, refer to

Figure 11A-34.

NOTE: T wo different sized bosses ar e supplied, fit the

correct one.

Figure 11A-33

Figure 11A-34

2.5 IDENTIFICATION PLATE, LABELS & BADGE

IDENTIFICATION PLATE

A Holden By Design identification plate is attached to

the front upper panel within the engine compartment.

Figure 11A-35

REAR DOOR LABELS

A Holden By Design label is affixed to the left-hand

and right-hand rear door quarter window.

Figure 11A-36

LIFTGATE BADGE

A Holden By Design label is affixed to the right-hand

side of the liftgate. It is aligned vertically central with

the Zafira emblem, and horizontally central between

the emblem and style line.

Figure 11A-37