Towbar US/CAN
Towbar US/CAN
INTRODUCTION
- NOTE: Read through the whole installation instruction before starting the work.
- The illustrations display the procedure in order of operation.
The order of operation is repeated in the text section
Towbar US/CAN
NOTE: The ball holder and ball with the accompanying components are not included in the towing member kit and must be purchased as separate kits.
NOTE:
Kit contents:
1. Towing member
2. Screw M12x100 (x4)
3. Screw M12x50 (x2)
4. Washer (x4)
5. Washer 24x13x7
6. Washer, heat deflector plate
7. Screw (4.8 x 9.5 mm)
8. Seal (4x)
9. Blind rivet (x12)
10. Locking bolt (purchased separately)
11. Strap (purchased separately)
12. Ball holder (purchased separately)
13. Ball (purchased separately)
14. Nut M16 (purchased separately)
15. Locking washer (purchased separately)
16. Locking pin (purchased separately)
17. Protective cover (purchased separately).
18. Cover
Cargo compartment, preparations
- Turn the ignition key to position 0 and 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 towbar, 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 and then pull out the clips.
- Remove the plastic nut.
- Repeat the operation on the right-hand side.
- Turn the knob on the right and left-hand sides a quarter turn. Fold the side panels inwards and remove them.
- Pull the tailgate sill trim panel (2) forwards on the right and left-hand sides until the two clips on each side release. The panel is tightly secured, but pull carefully in any case.
- Remove the wiring (3) for the cargo compartment lighting.
- Pull the sill trim panel straight up until the four clips on the underside 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 it to gain more space.
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-) / righthand (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 mudflaps
- Carefully drill out the rivets that hold the mudflap in place on both sides. Use a dia. 6 mm (1/4 inches) 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 dia. 6 mm (1/4 inches) diameter drill bit. Take care not to 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-hand side of the rear of the car. The bracket will not be used again.
- Install masking tape 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.
CAUTION: Particular care must be take when cutting out in the bumper for the R-line. The brackets for the air intake's mesh could be damaged.
- Leave the masking tape in place throughout the installation procedure.
Applies to cars from model year 2005- (CH 425000-)
- Cut along the markings on the inside of the bumper to make the cut-out for the towbar. Cut out so that the marking lines remain in the bumper afterwards.
Applies to cars up to and including model year -2004 (CH -424999)
- Use the cutting template from the kit to mark the cutting lines on the inside of the bumper. Position the cutting template as illustrated.
- Carefully mark out the cutting lines around the cutting template.
- Cut along the markings on the inside of the bumper to make the cut-out for the towbar. Cut out so that the marking lines remain in the bumper afterwards.
Applies only to R-line
- Apply masking tape on the outside of the exhaust pipe clip to avoid damage from the base of the saw.
Leave the masking tape in place during installation.
- Cut along the marked raised area and remove the cut-out area.
Applies to all models
- After cutting, smooth off the edges using a file.
Installing the towing member
Illustration A
- Clean any underseal and dirt from the mating surfaces between the towbar end face and the bodywork.
- Install the screws (2 and 4) from the underneath with the washers (3 and 5) 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) and secure it using the screw (7) for the washer plate (6).
- Reinstall the rubber mounting (8) for the silencer.
HINT: Use normal hand 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.
Installing the cable harness
- Install the cable harness for the towbar according to the Installation Instructions for the appropriate towbar wiring.
- When installing a 7-pin or 13-pin cable harness for the towbar, a cut-out (2) must be made for these in the lower edge of the bumper:
1. Loosely install the bumper. Make markings for the cut-out for the cable harness
2. Cut out as illustrated so that there is room for the cable harness.
Finishing work
- 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.
- Tighten the screw (1) on both sides.
- Secure both sides of the bumper with blind rivets (2) from below.
- Reinstall the bumper's nuts. Tighten the nuts. Tighten to 18 Nm (14 lbf.ft.).
Reinstall:
- The antenna connector
- The mudflaps, if applicable
- The rear wheels, tightening torque 140 Nm (103 lbf.ft.). Lower the car.
- Install new rubber tabs over the four newly installed nuts as follows:
- Align the rubber tabs (1, 4) edge to edge with the lining mat
- Compress the rubber tab (2) slightly to align in the cut-out
- Align the rubber tab (3) so that the lower edge is positioned edge to edge with the lining mat.
Then cut off the section protruding from the lining mat. Do not remove too much.
- If necessary, cut away the area around the screw heads, so that the screws are accessible.
Securing the ball holder
NOTE: Ball holder and ball purchased separately.
- Remove the cover from the towing member.
- Insert the ball holder into the towing member until the holes in the ball holder and towing member correspond.
- Slide the locking bolt into the hole.
- Lock the other side using the locking pin.
- Position the ball in the hole on the ball holder.
- Install washer and nut, torque tighten to 244 Nm (176.5 lbf.ft).
Storing the ball holder
- Remove the ball holder. Place the ball holder in the supplied storage bag.
- Place the bag with the ball holder in the spare wheel. The ball holder must be positioned as illustrated.
- Thread the strap through the two nearest holes in the wheel and around the ball holder.
- Insert the strap into the tensioner. Tighten the strap until the ball holder is secured.
Installing the protective cover
- Install the protective cover when the towbar is not in use.
Installing the decal
Illustration A applies to cars without integrated carrier bag holder in the cargo compartment floor
- Install the enclosed decal on the underside of the floor hatch as illustrated.
Illustration B applies to cars with integrated carrier bag holder in the cargo compartment floor
- Install the enclosed decal under the elastic strap on the underside of the floor hatch, as illustrated.
- In addition, use staples for the installation.
- 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.
- Remove the masking tape from the bumper.