SECTION 2A - TS SERIES ASTRA BODY KIT

1. GENERAL INFORM ATION

This Section of the Holden By Design Service Information Supplement describes the service procedures for the

aerodynamic id body sty ling kit components available for TS Astra Series Vehicles.

The id body styling kit c onsists of a newly designed integral front bum per fac ia / spoiler, rear bum per extension and

rear hatch spoiler. The original side skirts are modified to integrate with the styling package.

Alloy wheels, a chrom e ex haust extens ion, id and Holden By Design badging and a Holden By Design identification

plate are also included as part of the package.

NOTE: Vehicles can be supplied with only the rear spoiler or alloy wheels. In these instances no Holden By Design

identification or badging is included.

Figure 2A-1 illustrates the TS Astra id body kit major components.

For information not contained in this Supplement, refer to the Holden Astra on TIS 2000.

1.1 MAJOR COMPONENTS

Figure 2A-1

1. Front bumper facia 7. Rear bumper extension 3M stone chip film

2. Alloy wheel 8. Rear bumper extension

3. Side skirt 3M stone chip film 9. Exhaust extension

4. Side skirt (original part modified) 10. Rear spoiler

5. Holden By Design decal 11. Holden By Design emblem

6. id emblem 12. Holden By Design identification plate

2. FRONT BUMPER FACIA

A completely new front bumper facia is used which

replaces the original facia and includes an integral

front spoiler.

The bumper facia is painted in the vehicle’s body

colour. A replacement part is supplied unpainted and

will require painting prior to fitment. The painting

procedures are relatively straight forward, providing

the correct steps for refinishing PUR-RIM material

are followed.

As materials and techniques will vary depending on

the brand of paint us ed, painting procedures are not

provided in this Supplement. Refer to your paint

supplier if further information is required.

To accommodate access to the tow hook mount, a

cover is provided in the facia as shown.

Figure 2A-2

REMOVE

1. Remove the ambient temperature sensor by

depressing the tabs as shown and pushing the

sensor through the hole.

2. Remove the three scrivets (1), four Torx head

screws (2 & 3) and two scrivets (4) attac hing the

bumper facia to the vehicle, refer Fig. 2A-4.

3. Remove the bumper facia from the vehicle

ensuring to unclip the lug (5) from each side.

4. If the bumper f ac ia is not damaged, plac e it on a

soft surface to avoid scratches.

Figure 2A-3

Figure 2A-4

DISASSEMBLE

1. From the rear of the bumper facia, remove the

seven screws (1) and remove the wire mesh (2).

Figure 2A-5

INSTALL

1. Fit wire mesh to bumper facia with seven

screws as shown in Fig. 2A-5.

NOTE: If the new facia does not have screw holes,

drill a hole in each landing with a 2 mm drill bit.

2. Install facia onto vehicle ensuring the lugs (5)

are clipped into place, refer Fig. 2A-4.

3. Fit screws and scrivets as shown in Fig. 2A-4

and ensure bumper facia is correctly aligned.

3. SIDE SKIRTS

The original rocker panel side skirt assemblies are

integrated with the Holden By Design id kit by coating

the skirts with ‘Hi-Fill’ primer, which fills the grain of the

plastic material and provides a smooth finish. They are

then painted in the vehicle’s body colour.

Replacement parts are supplied unpainted and will

require f illing with a suitable Hi-Fill pr imer and painting

prior to fitment.

The painting procedures are relatively straight forward

providing the correct steps for refinishing

Polypropylene (PP) material are followed.

As materials and techniques will vary depending on

the brand of paint used, painting procedures are not

provided in this Supplement. Refer to your paint

supplier if further information is required.

REMOVE

1. Remove the scrivets (1 & 2) attaching the side

skirt to the vehicle, refer Fig. 2A-6.

NOTE: The centre pins of the scrivets do not have

heads, therefore the pin must be pushed inwards to

allow removal of the outer section. New scrivets will

be required on installation.

2. Remove the end cap (3) by sliding rearwards.

3. Remove the side skirt by first tapping the skirt

forward, then carefully unclipping it from the

vehicle in the direction shown.

4. If required, remove the nuts (5) attaching the

retain ers (6).

5. The retainer clip (7) may be left behind on

removal of the skirt and should be removed from

the vehicle.

Figure 2A-6

INSTALL

1. If required, paint the replacement part. Use Hi-

Fill primer to fill the grain of the polypropylene

and achieve a smooth finish.

2. Apply 3M stone chip film (1) to the front of the

sk irt as shown. Smooth out all trapped air as the

film is being applied.

NOTE: Ensure ar ea is clean and free of dirt, grease

and finger marks prior to affixing the film.

3. Ensure the retaining clip (7) is fitted into the

skirt, refer Fig. 2A-8.

4. If required fit the retainers (6) and nuts ( 5) to the

vehicle.

5. Align the skirt in position with the vehicle and

clip it in place by tapping at each retainer (6 &

7).

6. Fit the end cap (3) into the skirt by sliding it

forward, ensuring the tabs seat correctly in the

skirt.

7. Insert all scrivets, pushing their centre pin in

until flush with the outer head. Figure 2A-7

Figure 2A-8

4. REAR BUMPER EXTENSION

The rear bumper extension is secured to the rear

bumper facia with screws. Removal of the bumper

extension will necessitate rear bumper facia removal,

which is described below.

The rear bumper extension is painted in the vehicle’s

body colour. A replacement part is supplied unpainted

and will require painting prior to fitment.

The painting procedures are relatively straight forward,

providing the correct steps for refinishing PUR-RIM

material are followed.

As materials and techniques will vary depending on the

brand of paint used, painting procedures are not

provided in this Supplement. Ref er to your paint supplier

if further information is required.

REMOVE

1. Remove the tail lights by opening the access

cover inside the rear compartment and

removing the two thumb screws. Refer to

Service Instructions, Group N for Astra on TIS

2000, if further information is required.

2. Remove the Torx head screws (1) three places,

(2) three places each side and (3) seven places.

3. Remove the bumper facia and extension

assembly from the vehicle, sliding it over the

exhaust extension.

NOTE: When access is achieved, disconnect the

number plate light wiring connector.

Figure 2A-9

DISSASSEMBLE

1. If the bum per f ac ia is not damaged, plac e it on a

soft surface to avoid scratches.

2. Remove the six screws (1) from the inner side of

the bumper facia.

3. Remove the extension.

Figure 2A-10

INSTALL

1. Apply 3M stone chip film (1) to the front of the

extension as shown. Smooth out all trapped air

as the film is being applied.

NOTE: Ensure ar ea is clean and free of dirt, grease

and finger marks prior to affixing the film.

2. If the bumper facia has not been replaced

proceed to step 8.

Figure 2A-11

3. Place a small piece of caulking compound or

like, on the centre of each s crew hole landing as

shown.

4. Apply a daub of paint on the centre of the

caulking compound.

5. With the aid of an assistant, carefully fit the

extension in position, transferring the paint to

the bumper facia.

6. Remove the extension and compare the paint

mar ks with the bumper facia to ensure the paint

transferred correctly.

7. Drill the bumper f ac ia with scr ew holes using a 3

mm drill bit.

8. With the aid of an ass istant, place the extens ion

in its correct position.

9. Insert the screws to attach the extension to the

bumper facia.

NOTE: Adjustment may be required to ensure no

gaps exist along the top edge of the extension. If

required, apply a thin, smooth bead of Sikaflex or

equivalent along the edge.

Figure 2A-12

10. Drill the screw holes at each end of the

extension.

11. Fit the license plate light, if removed.

12. Install the bumper assembly in position,

connecting the license plate wiring connector.

13. Fit the screws attaching the bumper assembly,

16 places, refer Fig. 2A-9.

14. Refit tail lights and inner trim covers.

5. REAR SPOILER

The Holden By Design rear spoiler is mounted to the

tailgate by threaded studs which are encapsulated into

the spoiler and nuts. Fitment of the spoiler does not

interfere with the operation of the high mount stop light.

A replacement part is supplied unpainted and will

require painting prior to fitment.

The painting procedures are relatively straight forward,

providing the corr ect steps f or ref inishing PUR with rigid

structure foam core material are followed.

As materials and techniques will vary depending on the

brand of paint used, painting procedures are not

provided in this Supplement. Ref er to your paint supplier

if further information is required.

REMOVE

1. Open the tailgate and remove the two nuts (1)

and washers (2) attaching each side of the

spoiler (3) to the tailgate.

2. Remove the spoiler and ensure the seal (4)

remains with the spoiler.

Figure 2A-13

INSTALL

NOTE: If the tailgate has not been replaced,

proceed to Step 8.

1. Construct a drilling template from paper or light

card by photocopying or tracing Fig. 2A-15.

2. Place the tem plate (1) on the tailgate as shown,

ensuring the reference point (A) is aligned with

the edge of the rear windscreen moulding and

edge of the tailgate.

3. Mark the mounting hole centre points on the

tailgate.

4. Turn the template over and repeat for the other

side.

5. Sit the spoiler on the tailgate and ensure the

mounting studs align with the centre point

marks. Adjust as required.

6. Open the tailgate slightly and carefully drill 3mm

holes, followed by 8 mm holes completely

through the tailgate.

NOTE: Ensure not to drill into the water channel

below.

7. Debur the holes and apply primer to the bare

metal.

8. Ensure the seals are seated on each mounting

stud, refer Fig 2A-13.

9. Fit the spoiler to the tailgate and install the

washers and nuts and tighten.

Figure 2A-14

Figure 2A-15

6. ALLOY WHEELS

A unique 16” x 6” five spoke alloy wheel (1) is

available for the Holden By Design TS Astra, as part

of the id package or individually.

NOTE: As with all TS Astras, four-stud rims are

fitted to non-ABS vehicles. The five-stud rim as

shown is fitted to vehicles with ABS. The design of

the rim does not change.

The alloy wheels are fitted with 205/55 R16 V-rated

Dunlop Bathurst 1000 tyres. The standard steel rim

spare wheel is retained.

NOTE: The tyres are uni-directional. Always ensure

they are fitted in the correct direction of rotation.

This Section of the Holden By Design Service

Information Supplement illustrates the wheel type

only. For the inf orm ation requir ed to servic e wheels,

refer to the Astra Service Instructions on TIS 2000.

Figure 2A-16

7. EXHAUST EXTENSION

A chrome plated exhaust extension is fitted as part

of the Holden By Design id package.

REMOVE

1. Using a hammer and block of wood seated

against the front edge of the extension (1),

knock the extension off the exhaust pipe.

INSTALL

1. Sit the extension on to the end of the exhaust

pipe, ensuring correct orientation.

2. Carefully knock the extension onto the exhaust

using a rubber mallet until dimension shown is

achieved.

NOTE: Cover the extension with a soft rag to

prevent damage.

Figure 2A-17

8. IDENTI FICATION & BADGING

W her e a full Holden By Design id kit has been ins talled,

a HBD identification plate, Holden By Design decals, id

emblem s and a Holden By Design emblem are fitted to

the vehicle.

Figure 2A-18 shows the location of the HBD

identification plate. The identification plate is pop-

riveted to the vehicle using the existing holes in the

radiator support panel.

Figure 2A-18

Figure 2A-19 shows the location of the id emblem and

the positioning measurements on the C-pillar.

The emblem is affixed with double-sided tape.

Figure 2A-19

Figure 2A-20 shows the location of the Holden By

Design decal and the positioning measurements on

the rear door fixed glass.

The decal is self-adhesive.

Figure 2A-20

Figure 2A-21 shows the location of the Holden By

Design emblem and the positioning measurements on

the tailgate.

The emblem is affixed to the tailgate with double-

sided tape.

Figure 2A-21