GDW Tow Bar Fitting Instructions for Opel Cascada ('13-)
General Information and Safety Advice
This document provides fitting instructions and important advice for the GDW tow bar system designed for the Opel Cascada ('13-). Always follow the instructions carefully.
Important Advice
- Before starting, check the tow bar for any transport damage and ensure it is the correct reference for your vehicle.
- Read and follow all instructions in the fitting manual precisely.
- Present the tow bar under the vehicle before drilling or making any permanent attachments to confirm correct positioning.
- When drilling holes, ensure no electrical wires, brake lines, or fuel lines are present. Remove any soundproofing or bitumen coatings. Treat drilled holes and exposed metal with an anti-corrosive product.
- If the vehicle is equipped with non-standard bumpers (e.g., special series, sport kits, tuning modifications), consult GDW technical service to ensure compatibility.
- The tow bar is often delivered assembled for storage; disassemble the parts as required for installation.
Guarantee
- To determine the correct maximum towing weight for your vehicle, refer to the Certificate of Conformity (COC) or contact your vehicle dealer.
- Never exceed the specified technical limitations of the tow bar.
- The tow bar requires periodic checks:
- After the first 1,000 km of use.
- At least once a year thereafter.
- Checks should include:
- Verifying and retightening all bolts as necessary.
- Repairing any damage to the paint finish.
- Replacing any components damaged due to accidents or collisions.
- Greasing the internal parts of detachable tow bar systems.
Usage Guidelines
- If the towing ball obstructs the vehicle's license plate or fog light, it must be removed when the tow bar is not in use.
Technical Specifications
Trailer Weight Verification
To confirm your vehicle's maximum trailer weight, consult the Certificate of Conformity (COC) or your vehicle dealer. The tow bar's specifications must not be exceeded.
The D-value and S-value (vertical load on the ball) are critical for safe towing. Refer to your vehicle's documentation for these values.
Example calculations:
D = (Vehicle's max towing weight in kg * Vehicle's max towing weight in kg) / (Vehicle's Gross Vehicle Weight in kg) * 0.00981 ≤ 9.60 kN
S = Maximum vertical load on the ball (e.g., 75 kg)
Maximum trailer weight (e.g., 1700 kg)
Torque Values for Bolts
The following table lists recommended torque values for various bolt grades and sizes:
| Bolt Grade | M6 | M8 | M10 | M12 | M14 | M16 |
|---|---|---|---|---|---|---|
| 8.8 | 10.4 Nm | 25.0 Nm | 51.0 Nm | 87.0 Nm | 140.0 Nm | 215.0 Nm |
| 10.9 | 15.5 Nm | 37.0 Nm | 75.0 Nm | 130.0 Nm | 205.0 Nm | 310. Nm |
| 12.9 | 18.0 Nm | 43.0 Nm | 87.0 Nm | 150.0 Nm | 240.0 Nm | 370.0 Nm |
Required tools include: Socket wrenches (15, 17, 19 mm), .
Installation Steps
The following steps outline the general process for installing the tow bar. Refer to the diagrams for specific component placement and orientation.
Step 1: Access Mounting Points
Diagram shows the rear underside of the Opel Cascada, indicating access points for tow bar installation. Arrows ➡️ indicate fasteners to be removed or points of attachment.
Access the designated mounting points on the vehicle's chassis, typically located near the rear frame rails.
Step 2: Remove Rear Bumper and Trim
Diagram shows the rear bumper being detached from the vehicle. Arrows ➡️ indicate the direction of removal. A is shown, indicating its use.
Carefully remove the vehicle's rear bumper cover and any associated trim panels to gain access to the chassis mounting points. This may involve unscrewing fasteners or releasing clips.
Step 3: Prepare Chassis
Diagrams show close-ups of chassis areas where holes need to be drilled or existing holes are used. Arrows ➡️ indicate drilling locations or bolt paths. A is shown.
If drilling is required, locate the precise positions indicated in the diagrams. Ensure no wires or lines are present before drilling. Treat any newly drilled holes with an anti-corrosive agent.
Step 4: Mount Tow Bar Main Structure
Diagram shows the main tow bar assembly being positioned under the vehicle and aligned with the chassis mounting points. Fasteners are shown being inserted.
Position the main tow bar structure onto the vehicle's chassis, aligning it with the pre-drilled holes or mounting brackets. Insert the specified bolts and washers.
Step 5: Attach Tow Bar Brackets
Diagrams show specific brackets (labeled 1 and 2) being attached to the vehicle's chassis or the main tow bar structure using bolts and nuts.
Attach the primary tow bar mounting brackets to the vehicle's chassis using the provided hardware. Ensure correct orientation.
Step 6: Secure Tow Bar Assembly
Diagrams show the tow bar assembly being connected to the chassis brackets using bolts, nuts, and washers. Arrows ➡️ indicate tightening points. Tools like a socket wrench () are shown.
Connect the main tow bar structure to the chassis brackets. Insert and hand-tighten all bolts, nuts, and washers. Once all components are in place, tighten all fasteners to the specified torque values using the appropriate tools.
Step 7: Install Detachable Ball Neck
Diagrams show the detachable tow ball neck being inserted into the tow bar receiver and secured. A locking mechanism is indicated.
Insert the detachable tow ball neck into the tow bar receiver. Ensure it is correctly seated and locked according to the system's design.
Step 8: Electrical Connection
Diagram shows the electrical socket housing being mounted and connected, possibly with wiring harness integration. Components labeled A, B, C, D are shown.
Mount the electrical socket housing and connect the vehicle's wiring harness to the tow bar's electrical system. Follow specific wiring diagrams if provided separately.
Step 9: Final Checks and Clearances
Diagrams show the rear of the vehicle with the tow bar installed. One diagram shows specific dimensions and clearance requirements (R32.5, 210mm, 40mm, R15, 105mm) related to the tow ball and vehicle bodywork. Another diagram relates to vehicle weight limits.
Verify that all fasteners are tightened. Check that the tow ball and associated components do not obstruct the license plate, lights, or other essential vehicle functions. Ensure all required clearances, as per regulation nr. 55 and vehicle specifications, are met.
Refer to the vehicle's Certificate of Conformity (COC) for maximum permissible vehicle weights and towing capacities.
Clearance and Weight Regulations
Adherence to specific clearance zones around the tow ball is mandatory, as defined by regulation nr. 55 (Appendix VII, diagram 25 a,b). These clearances ensure safe operation and prevent interference with vehicle components or other road users.
The diagram illustrates these required clearances, including angles and distances (e.g., 65°, 45°, 100 mm max, 65 mm min, 250 mm max). It also shows the maximum permissible vertical load (S-value) and D-value, which must not be exceeded.
The document also references vehicle weight limits, such as the permissible total weight of the vehicle, which must be considered when towing.
