GDW Tow Bar Installation Guide for Hyundai Sonata (2005-2009)

General Specifications & Approval

EEC Approval Number: e6*94/20*0561*00

Maximum Towing Capacity (D): [Value not explicitly stated in kg, but implied by context]

Maximum Vertical Load (S): 75 Kg

Maximum Trailer Weight: 1800 Kg

Force Value (X): 9.65 KN (0.00981)

Parts List

• 1 x Ball (T43H006)
• 4 x Bolts M12x40 - DIN933
• 4 x Washers M12 - DIN128A
• 1 x Security shackle (800000)
• 1 x Fitting instruction manual
• 1 x Socket holder (P03)
• 4 x Stud bolts DIN961 - M10x1.25x35 - 8.8
• 1 x Left mounting piece (1)
• 2 x Plates (3)
• 6 x Washers DIN128A - M10
• 2 x Stud bolts DIN961 - M10x1.25x40 - 8.8
• 2 x Washers 40x35x12x4mm
• 2 x Washers 30x10.5x2.5mm
• 4 x Bolts DIN933 - M12x35 - 8.8
• 2 x Nuts DIN934 - M12 - 8.8
• 4 x Washers DIN128A - M12
• 1 x Right mounting piece (2)

All bolts and nuts are quality 8.8 unless otherwise specified.

Installation Instructions

1. Disassemble the bumper. Remove the buffer beam from the bumper and detach the bumper supports from the buffer beam. Re-mount the bumper supports to the chassis beam without fully tightening the bolts. Make an incision in the underside of the buffer beam (see Photo 1). Loosen the exhaust system and lower it, then remove the heat shield.
2. Position the left side piece (1) and the right side piece (2) with the filler plates (3) against the inner side of the chassis beams. Align points (A) and (B) with the pre-threaded holes in the chassis side. Insert bolts and washers without tightening.
3. Mount the tow bar between the mounting pieces (1) and (2), ensuring points (D) and (E) align. Insert bolts without tightening. Re-attach the buffer beam to the bumper supports. Firmly tighten the bolts at points (A) and (B) according to torque specifications. Re-attach the heat shield to the vehicle; one bolt from the original heat shield assembly will be omitted on the rear side of the vehicle.
4. Insert bolts with washers at points (C) and firmly tighten all bolts according to torque specifications. The heat shield is secured with the washer from point (C) (see Photo 2). Re-position the exhaust system.
5. Make an incision in the underside of the bumper and the spoiler (the black section) according to Figure 1 and Figure 2. Re-mount the bumper along with the spoiler onto the vehicle.
6. Assemble the ball coupling, socket holder, and security shackle. Insert and firmly tighten the bolts.

Bumper Disassembly Steps

To disassemble the bumper, the following components typically need to be removed:

• Rear lights: Remove 2x4 nuts in the trunk and pull lights backward.
• Plastic screws: Remove 2x2 plastic screws below the rear lights plus 2x1 small bolt.
• Bumper side bolts: Remove 2x2 bolts on the bumper's side behind the trunk lining.
• Self-tapping screws: Remove 2x2 self-tapping screws on the splashboard.
• Vertical bolt: Remove 1 small bolt vertically in the splashboard at the bumper corner.
• Trunk entrance screws: Remove 6 screws at the trunk entrance.
• Bottom nuts: Remove 4 nuts from the bottom of the bumper.
• Bottom bolts: Remove 4 M6 bolts from the bottom of the bumper on the left side of the plastic protection plate.

Diagram Descriptions

Photo 1: Shows the bumper beam with indicated cutouts of 25mm on each side for clearance.

Photo 2: A close-up view of a mounting point on the vehicle's chassis, illustrating the connection of a bracket.

Figure 1: Illustrates the underside of the bumper/spoiler, indicating a rectangular area of 140mm by 90mm that needs to be cut out.

Figure 2: Depicts bumper cutout details and provides torque specifications for various bolt sizes.

Clearance Diagram (Page 13): Technical diagrams illustrate clearance specifications required by directive 94/20/EG, detailing minimum and maximum dimensions and angles for safe operation.

Torque Specifications

Important Advice, Warranty, and Usage

General Advice

• Ensure the tow bar is undamaged during transport and is the correct reference for the vehicle.
• Read and follow the fitting instructions precisely.
• Present the tow bar under the car before installation to check alignment.
• When drilling, verify that no wires or lines can be damaged. Remove any soundproofing or bitumen coating. Treat drilled holes and chassis parts with an anti-corrosive product.
• If the vehicle has non-standard bumpers (sport, tuning parts), consult GDW's technical service before proceeding.

Warranty

• Do not exceed the indicated maximum towing weight, "D", and "S" values.
• The tow bar must be checked after the first 1,000 km of use and at least once annually.
• Check all bolt connections and retighten if necessary.
• Repair any paint damage.
• Replace any components damaged by an accident or collision.
• Grease the internal parts of detachable tow bar systems.

Usage

• If the tow ball obstructs the number plate or fog light, it must be removed when not in use.