Tow Hitch, Fixed

Tow hitch, fixed










































Tow hitch, fixed

Note!
Kit contents:
1. Crossmember
2. Screw M12 x 100 (x4)
3. Screws M12 x 50 (x2)
4. Washer (x4)
5. Washer, heat deflector plate
6. Screw (4.8 x 9.5 mm)
7. Seal (4x)
8. Blind rivet (x12)
9. Bracket
10. Pipe clamp
11. Flanged lock nut M8
12. Screw M8X25
13. Washer 24x13x7

Note! It is recommended that the work at steps 9, 13, 14 and 15 is carried out by two people.

Preparations




- Take the bracket for the trailer connector, the pipe clamp, M8 screw and accompanying lock nut from the kit.
- Install the bracket with the pipe clamp, the screw and the nut as illustrated. Tighten to 24 Nm (18 lbf.ft).

Note! The bracket must be located under the pipe clamp's level section.

- Turn the ignition key to position 0. Remove the ignition key from the ignition switch.
NOTE! Wait at least five minutes before disassembling the connectors or removing other electrical equipment.

- Install the cable harness connector for the tow hitch, according to the Installation Instructions for the appropriate cable harness.




- Fold up the floor hatch.
- Press the clips in the centre until a "click" is heard. Remove the clips.
- Remove the plastic nut.
- Repeat the operation on the right-hand side.




- Turn the handle (1) on the right and left-hand sides a quarter turn.
- Fold the side panels inwards. Remove the panels.
- Pull the tailgate sill trim panel (2) forwards on the right and left hand sides until the two clips on each side release. Carefully pull the panel with some force as it is tightly secured.
- Remove the wiring (3) for the cargo compartment lighting.
- Then pull the sill trim panel straight up until the four clips at the lower edge release. Remove the sill trim panel.





Remove:
- the two nuts from the front edge of the battery holder and the screw from the rear edge
- the battery holder
- the cover
- the battery negative lead
- the battery, or move the battery to facilitate access.

Illustration A





Remove:
- the four perforated sections (1) of the insulation panel
- the nuts (2) for the bumper
- the antenna connector (3).

Illustration B





Applies to cars with parking assistance
- Detach the parking assistance module (PAM) from its location on the left-hand (model year 2005-) / right-hand (model year -2004) side of the cargo compartment.
- Detach the smaller connector from the control module.

Preparations, rear suspension

- Raise the car.
- Remove the rear wheels.

Illustration A only applies to cars with mudguards




- Carefully drill out the rivets that hold the mudguard in place on both sides. Use a -6 mm (1/4") diameter drill bit.
- Remove the mudflaps.

Illustration B applies to all cars




- Unscrew the screw (1) almost all the way on the left and right-hand sides in the rear edge of the wheel arch.
- Press the screw using a screwdriver until the loose end pieces on the inside of the bumper cover are pressed backwards.
- Carefully drill out the rivets (2) underneath the bumper on both sides. Use a -6 mm (1/4") diameter drill bit. Do not damage any of the plastic components.

Note! There may be another installation procedure with more blind rivets on older cars.

Illustration A




- Pull the bumper backwards slightly. Bend out the sides (1) so that they detach from the mountings (2). Then pull the bumper backwards until it detaches completely.
- Place the bumper on a clean underlying surface that will not damage the paint.

Illustration B





Applies to cars with parking assistance
- Detach the bumper in accordance with the above. Carefully pull the cable (3) out through the hole in the car.
- Place the bumper on a clean underlying surface that will not damage the paint.





Remove:
- the rivet (1) on the bracket (2) for the silencer. Use cutting nippers
- the screws (3) on the bracket
- the bracket by detaching the rubber mountings (4). The bracket will not be used again.




- Remove the screws (1) and the bracket (2) from the right side of the rear of the car. The bracket will not be used again.

Illustration A applies to cars up to and including model year -2004 (CH -424999)




- Install masking tape (1) on the outside of the bumper to avoid damage from the base of the saw.
Install masking tape opposite the cutting points and over the bumper cover, as illustrated.
- Leave the masking tape in place throughout the installation procedure.
- Cut along the marking on the inside of the bumper, as illustrated.
- After cutting, smooth off the edges using a file.

Illustration B applies to cars from model year 2005- (CH 425000-)




- Install masking tape (1) on the outside of the bumper to avoid damage from the base of the saw.
Install masking tape opposite the cutting points and over the bumper cover, as illustrated.
- Leave the masking tape in place throughout the installation procedure.
- Cut along the marking on the inside of the bumper, as illustrated.
- After cutting, smooth off the edges using a file.

Installation, fixed tow hitch (incl. cable harness)

Illustration A




- Clean any underseal and dirt from the mating surfaces between the tow hitch end face and the bodywork.
- Install the screws (2 and 4) from the underneath with the washers (5 and 13) between. Finger tighten.
- Install a washer plate (6) on the left-hand side on the front screw (4). This is to secure the rear mounting for the heat deflector plate using the screw (7). (See illustration B).

Illustration B




- Install the heat deflector plate (1). Secure the heat deflector plate using the screw (7) for the washer plate (6).
- Reinstall the rubber mounting (8) for the silencer.

Hint: Use soap to facilitate installation of the rubber mounting.

Illustration A
- Tighten the screws (2). Tighten to 114 Nm (84 lbf.ft). Tighten the screws (4). Tighten to 81 Nm (60 lbf.ft), on both sides.
- Underseal the car.

Applies to Sweden only:
- Underseal after the state roadworthiness inspection.




- Install the cable harness for the tow hitch according to step 2 onwards in the Installation Instructions for the appropriate cable harness.
When installing a 7-pin or 13-pin cable harness for the tow hitch, a cut-out (1) must be made in the lower edge of the bumper.
- Loosely install the bumper. Make markings for the cut-out for the cable harness.
- Cut out as illustrated so that there is room for the cable harness.




- If the mountings (1) have released from the rear edge of the wheel arch, reinstall the mountings. Press the mountings completely back into their grooves and screw in the screw a few turns
- Applies to cars with parking assistance: Lift up the bumper in position. Pull the cable for the sensors through the hole for the bumper's guide, and pull the cable in from the inside.
- Reinstall the bumper by pressing it forwards. Ensure that the four screws protruding from the bumper align with the holes in the car.
- Before the bumper is completely installed, slide the top edge (2) into the grooves. Then slide the bumper fully in.




- Twist up the bracket with the trailer connector so that it is aligned straight and slightly away from the bumper.
- Align the cable harness in the cut-out and secure the bracket.
- Adjust the cable harness the whole way from the trailer connector and into the rubber grommet so that it does not hang under the car. Press the excess cable length in through the rubber grommet.
- Tighten the two tie straps (1) which were positioned earlier.




- Cut a cut-out (1) in the location where the cable harness exits from the inside of the bumper on the left-hand side of the tow hitch, and enters the rubber grommet in the floor.
- Remove the protective paper (2) from the bumper.

Finishing work




- Tighten the screw (1) on both sides.
- Rivet (2) the bumper on the underneath on both sides as illustrated
- Reinstall the nuts. Tighten the nuts to 18 Nm (14 lbf. ft.).
- Install the rubber seals to cover the four nut holes

Reinstall:
- the antenna connector
- the mudguards, if applicable
- the rear wheels. Lower the car.




- Applies to cars with parking assistance: Connect the detached cable to the parking assistance module (PAM). Reinstall the control module.
- Turn the ignition key to position II.

Reinstall:
- the battery, and connect the battery cables
- the cover
- the battery holder
- the tailgate sill trim panel, and plug in the connectors for the cargo compartment lighting
- the two side panels, incl. clips and plastic nuts
- Fold the floor hatch back into place.