Trailer Hitch: Service and Repair
Towbar, Hitch
INTRODUCTION
- NOTE: Read through the whole installation instruction before starting the work.
Towbar, hitch
Preparations
- Open boot lid.
- Remove the four bumper screws.
- Remove the screws on the bumper cover end. Repeat on the other side.
- Take hold of the bumper cover end and carefully pull it outward until the six catches release. Repeat on the other side.
NOTE: It is easier if two people work to remove the bumper.
- Pull the bumper straight back until the catches below the tail lamps release.
- Disconnect any parking assistance connectors.
- Place the bumper on a surface that will not damage the paint.
- Remove the impact member's styrofoam support.
- Clean any underseal and dirt from the inner member of the bumper where the L-profile for the towbar is to be located.
- Clean the metal flange on the inside and outside where the reinforcement stay is to be located.
Installation
- Install the L profile on the inner member of the bumper with four M10x25 flanged screws and corresponding flanged nuts. Do not tighten yet.
- Assemble the towbar wiring connector according to the separate installation instructions.
- Secure the connector to the towbar bracket.
- Fit the towbar retainer on the L profile using two M14x110 flanged screws and corresponding flanged nuts. Do not tighten yet.
The connector for the towbar wiring must sit on the lower screw.
11A
Applies to cars with 5-cylinder engine
- Place a support under the muffler.
- Detach the silencer's rubber mounting from its brackets on the right-hand and left-hand side.
11B
Applies to cars with 5-cylinder engines
- On some versions, the rear muffler has 2 rubber mountings on each side. The rear ones must be removed completely and not reused.
Applies to cars with 5-cylinder engine
- Remove the screws and brackets of the muffler mount on the right and left side.
Applies to cars with 4-cylinder engine
- Detach the rubber mounting for the end pipes from the bracket on the underside of the left-hand side member.
- Remove the screw and the bracket.
- Prise in the reinforcement stay from the back over the muffler.
- Install three M8x30 screws with washers on each side of the reinforcement stay. Install in the order illustrated. Do not tighten yet.
- Press the rear edge of the reinforcement stay upwards.
- Fit four M10x35 flanged screws, which are screwed through the towbar retainer in the reinforcement stay. Do not tighten yet.
- Tighten the L profile's four M10 screws (1) alternatingly so that the L profile and the inner member of the bumper lie against each other correctly. Tightening torque: 47 Nm (35 lbf.ft).
- Tighten the four M10 screws (2) of the towbar retainer and reinforcement stay alternatingly. Tightening torque: 47 Nm (35 lbf.ft).
- Tighten the six screws (3) for the reinforcement stay's front attachments in steps. Tightening torque 20 Nm (15 lbf.ft.) and then angle-tighten 90 degrees. There is not a lot of room to torque-tighten the middle screw, use special tool part no. 9997361 with a 3/8 inches socket extension.
- Check that the bracket's front edge (2) is parallel with the retainer's front edge (1).
- Torque tighten the two M14 screws to 200 Nm (147 lbf.ft).
- Install the towbar wiring following separate installation instructions.
- Refit the rubber mounting.
- Remove the support from under the muffler.
- Draw a new marking (dotted line). Start from the existing marking.
- Saw out the cut-out in the bumper cover in accordance with the markings made.
NOTE: Do not saw right out in the inner corners. Use a round file to create round corners.
- Finish by smoothing off the edges with a fine-toothed file.
NOTE: It is easier if two people work to install the bumper.
- Connect any parking assistance connectors and reinstall the bumper. Press so that the hooks under the tail lamps engage.
- Press until the catches for both ends of the bumper cover engage.
- Reinstall the screws.
- Remove the cover plug.
- Take the ball holder and insert it into the towbar retainer's square tube until the holes in the ball holder and square tube correspond.
- Insert the lock bolt through the holes and secure it with the locking pin.
- Position the ball in the hole on the ball holder.
- Install washer and nut. Torque tighten to 244 Nm (180 lbf.ft).
- Remove the towbar and reinstall the cover plug in the socket for the towbar.
Storing the towbar
Applies to cars without spare wheel
- Take the towbar, lock bolt and locking pin and insert them into the protective bag as illustrated. Secure the towbar and protective bag with the strap that is pulled through the luggage retainer's hook.
Steps 26-28 apply to cars with spare wheel
- Open the spare wheel compartment. Clean the inside of the wheel where foam tape shall be affixed.
- Install the foam tape as illustrated.
- Take the towbar, lock bolt and locking pin and insert them into the protective bag as illustrated. Secure the towbar and protective bag with the strap that is pulled through the holes in the rim.