Installation Instructions
- Remove the bumper and the metal buffer beam. Disconnect the exhaust system from the underside of the vehicle.
- Insert the supporting arms (1) (left) and (2) (right) into the chassis beams at the rear, through the openings created after removing the buffer beam. Ensure points (A) align with the pre-drilled holes on the underside of the chassis beam. Insert bolts and washers, but do not tighten yet.
- Position the mounting pieces (3) (left) and (4) (right) against the rear body panel, aligning points (D) with the threaded holes. Insert bolts and washers, but do not tighten. Points (B) and (C) should align with the holes in the supporting arms (1) and (2).
- Place the tow bar, aligning points (B) and (C) with the corresponding holes in the supporting arms. Insert bolts and tighten all bolts securely (refer to torque specifications).
- Mount the T45 fixing plates or the T36 detachable ball socket onto points (*). Place mounting pieces (5) on the outside of point (E), aligning with the opening in the towing eye. Insert filling pieces (6) between the towing eye and mounting plates (5), then insert the bolt. Attach the socket holder and security shackle at points (*), and insert bolts. Tighten all securely (refer to torque specifications).
- Make an incision in the underside of the bumper according to the provided diagram.
- Mount the ball coupling, insert bolts, and tighten firmly.
Bumper Disassembly
- 2 small bolts at the trunk entrance
- 2 plastic push rivets at the underside of the bumper
- 2x2 small screws at the wheel casings
- Detach side sections outwards
Parts List (Composition)
| Item | Description | Quantity | Notes / Location |
|---|---|---|---|
| Tow bar reference | 1505 | ||
| 1 | Ball coupling T45M025 | 1 | |
| Bolts M12x80 - DIN931 | 3 | (A-E) | |
| Bolts M12x65 - DIN931 | 2 | (*) | |
| Lock nuts M12 - DIN985 | 4 | (*-*) | |
| Security shackle | 1 | (*') | |
| T45 pieces | 2 | (*-*) | |
| T45 tubes | 2 | (*) | |
| Bolts M12x35 - DIN933 | 10 | (A-B-C) | |
| Lock washers M12 - DIN128A | 11 | (A-B-C-E) | |
| Nuts M12 - DIN934 | 3 | (B-E) | |
| Washers 40x35x12x4mm | 6 | (A) | |
| Washers 24x13x2.5mm | 4 | (B-C) | |
| Bolts M8x30 - DIN933 | 2 | (D) | |
| Lock washers M8 - DIN128A | 2 | (D) | |
| Washers 25x8.4x2mm | 2 | (D) | |
| Socket holder P04 | 1 | (*') | |
| Supporting arm left (1) | 1 | (A-B-C) | |
| Supporting arm right (2) | 1 | (A-B-C) | |
| Mounting piece left (3) | 1 | (B-C-D) | |
| Mounting piece right (4) | 1 | (B-C-D) | |
| Mounting pieces (5) | 2 | (*'-E) | |
| Filling up pieces (6) | 2 | (E) |
All bolts and nuts: quality 8.8
Technical Specifications & Diagram Descriptions
Bumper Cut-out Diagram
The diagram illustrates the required cut-out in the bumper. It indicates the following:
- The hatched area is the section to be removed.
- 'B' refers to the bumper itself.
- 'O' indicates the lower rim of the bumper.
- 'M' marks the middle of the bumper.
- Dimensions are provided: approximately 90mm width, 160mm height, with a specific cut-out shape including a 45.61mm radius.
Torque Specifications
Torque values for various bolt sizes are provided for different quality grades:
Quality 8.8
| Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|
| M6 | 10.8 | 1.1 |
| M8 | 25.5 | 2.60 |
| M10 | 52.0 | 5.30 |
| M12 | 88.3 | 9.0 |
| M14 | 137 | 14.0 |
| M16 | 211.0 | 21.5 |
Quality 10.9
| Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|
| M6 | 13.7 | 1.4 |
| M8 | 35.3 | 3.6 |
| M10 | 70.6 | 7.20 |
| M12 | 122.6 | 12.5 |
| M14 | 194 | 19.8 |
| M16 | 299.2 | 30.5 |
Clearance and Vehicle Weight Specifications
Diagrams illustrate clearance requirements for the tow bar installation, ensuring compliance with guideline 94/20/EG (Appendix VII, Diagram 30). Key specifications include:
- Maximum angles (e.g., 30°, 45°).
- Minimum and maximum dimensions (e.g., min 140mm, max 100mm, min 65mm, min 32mm, min 55mm).
- Radii for cut-outs (e.g., max R14.5, max R40).
- A vertical dimension of 350-420mm is indicated.
These clearances must be guaranteed for the vehicle's total permissible weight.
