General Instructions and Recommendations
Fitting and Mounting
Before commencing installation, ensure the towbar has not been damaged during transport and that it is the correct reference for the vehicle. Carefully read and follow all instructions provided in the mounting manual. Present the towbar under the vehicle before starting the actual mounting process to verify alignment. If drilling is required, check for and avoid damaging any electrical wiring, brake lines, or other components. After drilling, clean the holes and surrounding bodywork, then treat them with an anticorrosive product. If the vehicle is equipped with non-standard bumpers (e.g., special editions, sport packages, tuning parts), it is imperative to contact GDW's technical service before proceeding to ensure compatibility. The towbar delivered is typically assembled for storage; disassemble parts as needed for installation.
Guarantee
To determine your vehicle's correct towing capacity, refer to the Certificate of Conformity (COC) or consult your vehicle dealer. Do not exceed the towbar's specified technical limits. The towbar must be checked after the first 1,000 km of use and at least once annually. This check should include: tightening all bolts as necessary, repairing any paint damage, replacing any components damaged by an accident or impact, and greasing the internal parts of detachable towbar systems.
Usage
If the towball obstructs the license plate or fog light, it must be removed when the trailer is not attached.
Important Recommendations (Multilingual Summary)
- Dutch (NL): Check for transport damage. Follow instructions precisely. Present towbar before drilling. Protect drilled holes from corrosion. Contact GDW for non-standard bumpers. Disassemble for storage. Check vehicle COC for towing capacity. Regular checks (1000km, annual) for bolts, paint, and detachable parts. Remove towball if it covers license plate or fog light.
- French (FR): Ensure towbar is undamaged. Follow instructions carefully. Present towbar before fitting. Treat drilled holes with anti-corrosive product. Consult GDW for special bumpers. Disassemble for storage. Verify vehicle's towing capacity (COC). Regular checks (1000km, annual) for hardware, paint, and detachable parts. Remove towball if it covers license plate or fog light.
- German (DE): Check for transport damage. Follow instructions carefully. Present towbar before mounting. Protect drilled holes from corrosion. Contact GDW for non-standard bumpers. Disassemble for storage. Check vehicle COC for towing capacity. Regular checks (1000km, annual) for bolts, paint, and detachable parts. Remove towball if it covers license plate or fog light.
- Spanish (ES): Ensure towbar is undamaged. Follow instructions carefully. Present towbar before fitting. Treat drilled holes with anti-corrosive product. Consult GDW for special bumpers. Disassemble for storage. Verify vehicle's towing capacity (COC). Regular checks (1000km, annual) for hardware, paint, and detachable parts. Remove towball if it covers license plate or fog light.
- Danish (DK): Check for transport damage and vehicle fit. Follow instructions. Treat drilled holes with rust-inhibiting agent. Contact GDW for special bumpers. Ensure bolts/nuts have good friction. Remove underbody protection where towbar mounts. Bolts must be retightened after 1000km. No modifications (welding, drilling) allowed. Replace if damaged by accident. Do not exceed load/ball weight limits. Towball must be clean and greased. Measure ball diameter regularly (min 49mm). GDW not liable for incorrect installation/use. Remove towball if it covers license plate or fog light.
Installation Steps
Common Steps (Hyundai i40 & Kia Optima)
Steps 1-2: Access and Exhaust Removal
Open the vehicle's trunk. Access the rear underside of the vehicle. Remove the exhaust silencer(s) as shown in Diagrams 9 and 10. This may involve unbolting or unhooking the exhaust system.
Diagram 9: Shows access to the rear underside and the exhaust system for removal.
Diagram 10: Illustrates the process of removing the exhaust silencer, possibly with a tool like a jigsaw [jigsaw icon] or wrench [wrench icon].
Steps 3-4: Rear Bumper Removal
Open the vehicle's trunk. Remove the rear bumper by releasing fasteners on both sides, as indicated by arrows in Diagrams 11 and 12. This typically involves removing screws or clips.
Diagram 11: Shows the rear of the car with the trunk open, indicating removal of the bumper from the left side.
Diagram 12: Shows the rear of the car with the trunk open, indicating removal of the bumper from the right side.
Steps 5-6: Side Trim/Fender Liner Removal
Remove side trim panels or fender liners on both sides of the rear bumper area as shown in Diagrams 13 and 14. This may require tools such as a PZ1 screwdriver [PZ1 screwdriver icon], PZ2 screwdriver [PZ2 screwdriver icon], or a 10mm socket [10mm socket icon].
Diagram 13: Illustrates the removal of trim panels on the left side, showing required tools.
Diagram 14: Illustrates the removal of trim panels on the right side, showing required tools.
Steps 7-8: Inner Fender Liner Removal
Remove the inner fender liners on both sides of the vehicle as depicted in Diagrams 15 and 16. Tools such as a PZ2 screwdriver [PZ2 screwdriver icon] and an 8mm socket [8mm socket icon] may be needed.
Diagram 15: Shows removal of inner fender liner on the left, with tools.
Diagram 16: Shows removal of inner fender liner on the right, with tools.
Steps 9-10: Accessing Mounting Points
Access the vehicle's chassis mounting points on both sides as shown in Diagrams 17 and 18. Tools like a 10mm socket [10mm socket icon] or a 12mm socket [12mm socket icon] might be used.
Diagram 17: Shows access to mounting points on the left side.
Diagram 18: Shows access to mounting points on the right side.
Steps 11-12: Bumper Modification (Cutting)
Modify the rear bumper by cutting out a section according to the template and measurements provided in Diagrams 23-24 and 33-34. Use a jigsaw [jigsaw icon]. Specific measurements include 200mm length, 60mm height, and R32.5 radius (Diagram 34), or 380mm length with a 45mm offset (Diagram 36), or 200mm, 120mm, 90mm, 50mm dimensions with R32.5 radius (Diagram 38).
Diagram 23: Shows the towbar assembly and indicates bumper modification is needed.
Diagram 24: Shows the rear of the car with the bumper removed, ready for modification.
Diagram 33: Shows the towbar assembly being positioned for bumper fitting.
Diagram 34: Provides detailed measurements for cutting the bumper, including a jigsaw icon.
Diagram 35: Shows the towbar assembly being positioned for bumper fitting.
Diagram 36: Provides measurements for bumper modification, including a jigsaw icon.
Diagram 37: Shows the towbar assembly being positioned for bumper fitting.
Diagram 38: Provides detailed measurements for cutting the bumper, including a jigsaw icon.
Steps 13-14: Bumper Re-fitting
Re-fit the rear bumper, ensuring all clips and fasteners are securely attached as shown in Diagrams 39 and 41-42.
Diagram 39: Shows the rear bumper being re-fitted.
Diagram 41: Shows the bumper being re-fitted on the left side.
Diagram 42: Shows the bumper being re-fitted on the right side.
Steps 15-16: Re-attaching Exhaust
Re-attach the exhaust system components as shown in Diagrams 41 and 42.
Diagram 41: Shows re-attaching the exhaust system on the left.
Diagram 42: Shows re-attaching the exhaust system on the right.
Steps 17-18: Final Towball Assembly
Assemble the chosen towball type (e.g., fixed or detachable) to the towbar assembly as depicted in Diagram 43. Refer to the parts list for available options. Use a 19mm wrench [19mm wrench icon] for tightening.
Diagram 43: Illustrates the assembly of different towball types (A, B, L) onto the towbar, showing components C and D for attachment.
Step 19: Clearance and Weight Information
Ensure all components are securely fastened. Check clearance requirements as per regulation nr. 55, as illustrated in Diagram 32. Note the vehicle's permissible total weight and towing capacity.
Diagram 32: Details clearance specifications (dimensions and angles) and towing weight information.
Hyundai i40 Specific Steps
Steps 21-22: Bracket Attachment (Left Side)
Attach the left mounting bracket (Part 2) to the vehicle chassis using bolts (Part 8) and nuts (Part 10). Use washers (Part 7) as shown. Torque bolts to specification [torque spec].
Diagram 19: Shows attaching the left bracket (Part 2) to the chassis using parts 7, 8, 9, 10.
Diagram 20: Shows securing the left bracket (Part 2) with parts 8, 9, 10.
Steps 23-24: Bracket Attachment (Right Side)
Attach the right mounting bracket (Part 3) to the vehicle chassis using bolts (Part 8) and nuts (Part 10). Use washers (Part 7) as shown. Torque bolts to specification [torque spec].
Diagram 25: Shows attaching the right bracket (Part 3) to the chassis using parts 8, 10.
Diagram 26: Shows securing the right bracket (Part 3) with parts 8, 10.
Steps 25-26: Towbar Main Body Attachment
Attach the towbar main body (Part 1) to the chassis brackets using bolts (Part 8) and nuts (Part 10). Torque bolts to specification [torque spec].
Diagram 27: Shows attaching the towbar main body (Part 1) to the left bracket using parts 8, 10, and 5 (Kia Optima specific).
Diagram 28: Shows attaching the towbar main body (Part 1) to the right bracket using parts 8, 10, and 6 (Kia Optima specific).
Steps 27-28: Towbar Main Body Attachment (Continued)
Attach the towbar main body (Part 1) to the chassis brackets using bolts (Part 8) and nuts (Part 10). Torque bolts to specification [torque spec].
Diagram 27: Shows attaching the towbar main body (Part 1) to the left bracket using parts 8, 10, and 5 (Kia Optima specific).
Diagram 28: Shows attaching the towbar main body (Part 1) to the right bracket using parts 8, 10, and 6 (Kia Optima specific).
Steps 29-30: Bumper Reinforcement and Towbar Mounting
For Hyundai i40, specific modifications or attachments to the bumper reinforcement or inner panels may be required, as indicated in Diagrams 39 and 40. Diagram 40 shows specific cutting guides (A and B) for the Hyundai i40.
Diagram 39: Shows the rear bumper being re-fitted.
Diagram 40: Shows specific cutting guides (A, B) for the Hyundai i40 bumper reinforcement.
Kia Optima Specific Steps
Steps 31-32: Bracket Attachment (Left Side)
Attach the left mounting bracket (Part 5) to the vehicle chassis using bolts (Part 13) and nuts (Part 12). Torque bolts to specification [torque spec].
Diagram 21: Shows attaching the left bracket (Part 5) to the chassis using parts 12, 13, 14.
Diagram 22: Shows securing the left bracket (Part 5) with parts 12, 13, 14.
Steps 33-34: Bracket Attachment (Right Side)
Attach the right mounting bracket (Part 6) to the vehicle chassis using bolts (Part 13) and nuts (Part 12). Torque bolts to specification [torque spec].
Diagram 21: Shows attaching the left bracket (Part 5) to the chassis using parts 12, 13, 14.
Diagram 22: Shows securing the left bracket (Part 5) with parts 12, 13, 14.
Steps 35-36: Towbar Main Body Attachment
Attach the towbar main body (Part 1) to the chassis brackets using bolts (Part 13) and nuts (Part 12). Torque bolts to specification [torque spec].
Diagram 27: Shows attaching the towbar main body (Part 1) to the left bracket using parts 8, 10, and 5 (Kia Optima specific).
Diagram 28: Shows attaching the towbar main body (Part 1) to the right bracket using parts 8, 10, and 6 (Kia Optima specific).
Steps 37-38: Towbar Main Body Attachment (Continued)
Attach the towbar main body (Part 1) to the chassis brackets using bolts (Part 13) and nuts (Part 12). Torque bolts to specification [torque spec].
Diagram 27: Shows attaching the towbar main body (Part 1) to the left bracket using parts 8, 10, and 5 (Kia Optima specific).
Diagram 28: Shows attaching the towbar main body (Part 1) to the right bracket using parts 8, 10, and 6 (Kia Optima specific).
Steps 39-40: Bumper Reinforcement and Towbar Mounting
For Kia Optima, specific modifications or attachments to the bumper reinforcement or inner panels may be required, as indicated in Diagrams 29-30. Diagram 29 shows the towbar assembly and components, and Diagram 30 shows the overall positioning for bumper re-fitting.
Diagram 29: Shows the towbar assembly and components, including optional parts.
Diagram 30: Shows the towbar assembly being positioned for bumper re-fitting for both Hyundai i40 and Kia Optima.
Additional Information
Vehicle Weight Limits: Refer to Diagram 32 for information on permissible total vehicle weight and towing capacity. Ensure these limits are not exceeded.
Clearance Specifications: Diagram 32 provides essential clearance specifications conforming to regulation nr. 55, including dimensions and angles that must be maintained.
Tools Required: Various tools are indicated throughout the manual, including socket wrenches (e.g., 8mm, 10mm, 12mm, 19mm), screwdrivers (PZ1, PZ2), and a jigsaw [jigsaw icon] for bumper modifications.
Warning: Always consult the vehicle's owner manual and safety guidelines before performing any modifications or installations. The manufacturer is not liable for issues arising from incorrect installation or use.
Contact GDW: For any questions or if your vehicle has non-standard bumpers, contact GDW technical service.
Website: www.gdwtowbars.com
