Chevrolet Nubira Break Tow Bar
Model: 10/2004 onwards
GDW Reference: 1497
EEC Approval Number: e6*94/20*0512*00
Technical Specifications:
- D-Value Calculation: D = (max trailer mass in kg * max trailer mass in kg) / (max trailer mass in kg + max trailer mass in kg) * 0.00981 ≤ 7.50 kN
- Maximum Vertical Load (S/): 75 kg
- Maximum Towing Mass: 1200 kg
Product Overview
This document provides installation instructions and component details for the GDW tow bar system designed for the Chevrolet Nubira Break, manufactured from October 2004 onwards.
Image: A black Chevrolet Nubira Break station wagon is shown.
Tow Bar Assembly Diagram Description
A technical diagram illustrates the tow bar assembly. It depicts the main tow bar structure, mounting brackets, the ball hitch, and various attachment points. These points are identified by labels such as letters (A, B, C, D, E, S) and numbers (1, 2, 3, 4, 5), along with specific component references like P03 and an asterisk (*).
Installation Instructions
- Remove the side and floor coverings from inside the luggage compartment.
- Remove bolts located inside the luggage compartment near the rear wall. After removing any bitumen coating, place the plates (ref. 1) with points (A) onto the existing holes and insert the special bolts finger-tight. Drill holes (B) and (C) (marked by an indentation on the plate) to Ø10.5mm. Remove the plates and enlarge these holes to Ø19.5mm. Insert the filler tubes (ref. 2) through the luggage compartment into the chassis beams and reposition the plates. Insert bolts at points (A), (B), and (C), tightening only the bolts at point (A) firmly (refer to torque specifications).
- Attach the mounting pieces (ref. 3) and (ref. 4) with points (A), (B), and (C) onto the inserted bolts against the underside of the chassis beams. Insert nuts and security washers without tightening.
- Position the tow bar with points (D) and (E) between the mounting plates, aligning the holes. Insert bolts with security washers and tighten everything firmly (refer to torque specifications).
- Reassemble any parts removed in step 1.
- Mount the ball T43 or the housing of the detachable system T35 along with the socket plate and the safety shackle. Place the plate (ref. 5) on top of the tube and insert the bolts. Tighten everything firmly (refer to torque specifications).
Component Composition
| Item | Part Name/Number | Quantity | Reference Points |
|---|---|---|---|
| 1 | Ball T43L006 | 1 | (*-') |
| 2 | Bolts M12x40 - DIN933 | 2 | (*) |
| 3 | Bolts M12x100 - DIN931 | 2 | (*') |
| 4 | Security washers M12 - DIN128A | 8 | (*-*'-D-E) |
| 5 | Nuts M12 - DIN934 | 6 | (*-*'-E) |
| 6 | Security shackle (-s) | 1 | (*-*') |
| 7 | Bolts M10x140-1,25 - DIN960 | 2 | (A) |
| 8 | Nuts M10-1,25 - DIN934 | 2 | (A) |
| 9 | Bolts M10x110 - DIN931 | 4 | (B-C) |
| 10 | Nuts M10 - DIN934 | 4 | (B-C) |
| 11 | Security washers M10 - DIN128A | 6 | (B-C) |
| 12 | Bolts M12x35 - DIN933 | 4 | (D-E) |
| 13 | Main tube plate (5) | 1 | (*') |
| 14 | Plates (1) | 2 | (A-B-C) |
| 15 | Tubes 19x3mm (2) | 4 | (B-C) |
| 16 | Side piece left (3) | 1 | (A-B-C-D-E) |
| 17 | Side piece right (4) | 1 | (A-B-C-D-E) |
| 18 | Socket holder P03 | 1 | (*) |
Note: All bolts and nuts are quality 8.8, unless otherwise specified.
Torque Specifications
For Bolts/Nuts 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 |
For Bolts/Nuts 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 |
(Specifications for DIN 912, DIN 931, DIN 933, DIN 7991 bolts)
Clearance Specifications
The installation must comply with clearance requirements as specified in Supplement VII, diagram 30 of guideline 94/20/EG. These include specific angles and dimensions to ensure proper fitment and safety.
Diagrams show side clearance angles (max. 45°, max. 30°) and dimensions (e.g., min. 140, max. 100, min. 65, min. 32, min. 55). Another diagram illustrates rear clearance angles (max. 30°) and dimensions (min. 75, max. R40, max. R14.5), along with overall height dimensions (350-420mm).
These specifications are relevant for the permissible total weight of the vehicle.
Important Notes
- For the maximum permissible towing mass for your vehicle, consult your vehicle dealer or owner's manual.
- Remove any bitumen coating or anti-vibration material from the fastening points before installation.
- Exercise caution when drilling to avoid damaging brake lines, electrical wiring, or fuel lines.
