Hayman Reese Towbar Installation Instructions

Part Number: 03310RW

Vehicle: Suzuki Vitara LY Series II

This document provides detailed instructions for the installation of the Hayman Reese Towbar for the Suzuki Vitara LY Series II. Please read all instructions carefully before beginning the installation process.

Product Details:

Fitting Details:

Note: Electric Brake Input Location: Near Blue Connector. RPA Disable: Via switch on dashboard.

Before You Start:

• Hayman Reese recommends reading instructions completely prior to fitment.
• Check all hardware items are included, referring to the assembly diagram.
• Ensure this towbar is only fitted to vehicle models as per the Hayman Reese application guide (www.haymanreese.com.au).

Bumper Cuts:

Vehicle and bumper variations can occur. Assess the fitment of the towbar and the accuracy of the bumper cut before making any modifications. Incorrect bumper cuts are not covered under Hayman Reese warranty.

Note: Bumper cuts need to be approached with care. Refer to notes below.

• Bumper Centreline: Determine the centreline by measuring the bumper width or identifying two symmetrical reference points.
• Bumper Edge: To accurately measure the bumper cut, reference the start of the bumper edge. Measure 70 mm from the bottom edge along the bumper and around the corner. Do not measure from the visible front of the bumper corner upwards.

Drilling:

• Ensure the area is clear of fuel, electrical, and other components that may be damaged during drilling.
• Coat all drilled holes with a suitable rust preventative paint after removing burrs and swarf.

Bolts/Fasteners:

• Fasten all hardware to the correct torque specified in these fitting instructions.
• Use fasteners of the same grade and class if replacements are required.

Note: Achieving correct torque is critical for proper installation and is the installer's responsibility. Towbar failures due to tension issues are not covered by Hayman Reese warranty.

Product Labels:

• a. The towbar load rating sticker should be conspicuously located on the inside rear end of the driver's door.
• b. A Powertrain Control Module (PCM)/Body Control Module (BCM) upgrade warning label will be provided for vehicles as required. Affix this label in the door and the owner's handbook.

[Image: Diagram showing placement of Load Rating sticker inside driver's door and Vehicle PCM/BCM upgrade warning label in door and on owner's service handbook.]

WARNING: Do not drill, cut, weld, or otherwise modify the towbar. This towbar is designed and tested by Hayman Reese to adhere to ADR 62/02 for towing purposes only.

Towbar Assembly Diagram:

Installation Steps:

1. Remove 2 x bolts and 4 x scrivets from the underside of the bumper.
2. In the wheel arch, remove 1 x screw and 1 x scrivet. Repeat for the opposite side.
3. Peel back the wheel arch trim. Underneath the wheel arch trim, remove 1 x scrivet and 1 x screw. Repeat for the opposite side.
4. Remove 2 x screws securing the tail light and 2 x bolts securing the top side of the bumper. Repeat for the opposite side.
5. Carefully remove and disconnect the tail light. Keep it in a safe place for re-attachment. Repeat for the opposite side.
6. Carefully remove the bumper by peeling away at the edges, ensuring to disconnect wiring connections. Keep it in a safe place for re-attachment. Disconnect any factory-fitted parking sensors.
7. Remove and discard the impact beam, secured to the chassis with 4 x nuts per side. Ensure wiring is detached from the impact beam before removal.
8. Insert the sidearm into the chassis rail and loosely secure with 1 x M10 bolt complete with 1 x washer using the mounting point towards the front of the vehicle. Repeat for the opposite side.
9. Using two people, lift the centre section of the towbar up to the sidearms and secure by aligning holes on the sidearms with 6 x M10 bolts complete with 2 x washers and 1 x nut per bolt, and 2 x M10 bolts complete with 1 x washer per bolt (secured into the centre section captive nut). Torque all fasteners as follows: M10x1.5P G10.9: 62 Nm
10. On the bottom edge of the bumper, locate the centre vertical. Cut approximately 100mm wide and 120mm up from the edge, as measured along the outside face of the bumper.
11. Mark out and drill 2 x ø5mm holes 69mm apart on the bumper skin to support the plug bracket. Feed bracket threads through drilled holes prior to reinstalling the bumper.
12. Re-attach the bumper by following steps 1-6 in reverse.

Wiring Installation:

IMPORTANT: Due to possible vehicle variations, always confirm any noted vehicle colour wires with a multimeter to ensure the correct function is identified before soldering or scotch locking. For vehicle wires denoted with two colours (e.g., RED/GREEN), the first colour is the main wire colour, and the second colour is the thinner trace colour on the wire.

13. In the engine bay, disconnect the vehicle battery negative terminal (1).
14. In the luggage compartment, remove the boot liner (1).
15. Remove the spare wheel floor cover.
16. Remove the rear sunshades (2).
17. Fold the rear seats down (3).
18. On the rear sill trim (1), remove the two scrivets (2).
19. Dislodge the rear sill trim by pulling in an upwards direction and carefully disconnect the smart key antenna if fitted.
20. Remove the LHS and RHS luggage compartment bolts (1).
21. Remove the LHS and RHS (2) clips next to the weather seal. Note: Twist and pull the clip to remove.
22. Dislodge the LHS and RHS trim.
23. On the LHS of the luggage compartment, disconnect the tail light assembly connector.
24. Connect the supplied Trailer Patch (102239-WL) LHS (labelled LHS) mating connectors (1) in between the tail light assembly connectors (2).
25. Route the long branch of mating connectors (labelled RHS) to the RHS of the vehicle.
26. Patch in the RHS mating connectors between the vehicle harness and the tail light harness.
27. In the vehicle below the LHS tail light, route the orange wire (1) towards the front of the vehicle.
28. Secure the ground wire terminal (2) to a suitable area on the vehicle chassis.
29. Using an alcohol wipe, clean the LHS inner sheet metal area (3) and the underside of the ECU (04826).
30. Connect the trailer patch 12-way connector to the ECU.
31. Apply double-sided tape to the ECU and secure it to the vehicle sheet metal. Note: Mount the ECU, ensuring the connector is oriented downwards.
32. At the rear LHS rear passenger door, remove the sill trim (1).
33. In the driver's kick panel area, remove the LHS front sill trim (1).
34. Remove the LHS driver's kick panel (2).
35. Remove the carpet under the glove box (3) by removing the 3 scrivets (4).
36. Remove the black cover on the fuse box.
37. Route the orange power wire (1) up to the vehicle fuse box on the LHS of the vehicle. Tuck the wire behind the B pillar trim as the wire is routed.
38. On the vehicle fuse box, remove the vehicle fuse and discard.
39. On the Add-A-Fuse (1), insert the supplied 20 amp fuses (2) into the Add-A-Fuse top and bottom slot.
40. In the orientation shown, insert the Add-A-Fuse into the slot where the previously removed fuse was located.
41. Connect the Add-A-Fuse (1) to the main harness (3). Note: To maintain correct electrical operation, ensure you insert the fuse adaptor into the allocated slot and in the orientation shown.
42. In the luggage compartment, drill a 30mm grommet hole (1) in a suitable location to enable the tail harness to be routed from the towbar to the ECU.
43. With the rear bumper removed, secure the tail harness (2) to the towbar.
44. Route the tail harness up through the chassis rail and the previously removed vehicle blanking grommet.
45. Seat the grommet in the 30mm blanking hole and route to the trailer harness blue connector on the wiring loom. Note: Keep harness routing clear of all sharp edges, moving parts, and places of extreme heat. Ensure the grommet is seated correctly and makes a good seal.
46. Connect the tail harness (tail length 1200mm) 8-way connector to the trailer patch mating 8-way connector. Note: Factory RPA system can be disabled via a switch on the dash.
47. Secure all harnesses using supplied Cable Ties.
48. Test the trailer patch function using a light board or multimeter.
49. Re-fit all removed parts and secure all fasteners, ensuring there are no squeaks or rattles.
50. Place the fitting instructions in the glove box after fitment.

Towbar Maintenance and Care:

Thank you for purchasing Hayman Reese. With correct maintenance and care, this product will provide a lifetime of trouble-free operation.

1. Hayman Reese recommends that the towbar LUG or TBM (Tow Ball Mount) Pull Pin and R-clip are removed and stored when not in use. Removal of the LUG or TBM is advisable when not in use to assist with:
   • Ensuring the rear number plate is not obscured.
   • Allowing maximum available departure angle and preventing potential interference.
   • Preventing possible interference with vehicle reverse sensors or cameras detecting a tow ball mount as an obstruction during reversing.
   • Removing the towball mount as an obstruction when moving around the rear of the vehicle.
2. Hayman Reese recommends routine inspection of your towbar to ensure trouble-free towing.
• Bolt security and tension should be regularly inspected and checked for correct tension. Replace any worn or defective parts with suitable grade & class fasteners. Inspection should coincide with vehicle major services.
3. It is the owner's responsibility to ensure towing and down ball weight capacities of the towing vehicle are not exceeded.
• Towing and down ball weights allowable may differ according to model variations. Please refer to the owner's manual or vehicle dealer to confirm the exact rating for your vehicle model variant.
• It is not uncommon for the vehicle tow rating to differ from the towbar rating. When this occurs, the lesser rating must be adhered to.
• For vehicles fitted with enhanced vehicle functions that may be altered/changed when towing (e.g., Trailer sway mitigation, blind spot detection, adaptive cruise control), please consult the owner's manual to understand changes enabled when towing and after towing.

Warranty Information:

Hayman Reese Towbars are covered by a Lifetime Warranty. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. For further details please visit www.haymanreese.com.au/warranty or contact customer service on 1800812017 or info@haymanreese.com.au.

Customer Information:

Place these instructions in the vehicle's glovebox after installation.

Hayman Reese Smart Pin:

Your Hayman Reese towbar is equipped with Smart Pin technology to help reduce towbar tongue rattle in most driving conditions. Please ensure the below instructions are understood and routine maintenance is carried out to ensure the best towing experience.

• Regularly inspect for wear and check the tightness of the Smart Pin Nut. Follow instructions below to retighten the nut as necessary when movement and noise in the tow ball mount is noted.
• Before towing, ensure the R-Clip is properly installed and the Smart pin nut is installed and tensioned. Replacement parts are available from your Hayman Reese Distributor.

Towball Mount Removal/Installation:

Step 1

Insert Trailer Ball Mount (TBM) (a) into towbar hitchbox (b), aligning the hole in the TBM shank (c) with the hole in the hitchbox (d) (Fig. 1).

Step 2

Insert Smart Pin (e) through the hole in the hitchbox and the hole in the TBM shank (g); ensure the locators are inserted into the notches in the hitchbox (Fig. 2).

Step 3

Screw Smart Pin Nut (f) onto Smart Pin (g); tighten Smart Pin Nut until finger tight, ensuring the TBM is restrained from up and down movement.

Step 4

Tighten Smart Pin Nut by turning the nut a further 1/8th of a turn in the clockwise direction using a 24mm spanner (Fig. 4).

Step 5

Install Smart Pin R-Clip through the hole that provides best clearance or easiest access. (Fig. 5)