Westfalia Tow Bar Installation Guide
Isuzu D-Max (2012-)
Part Number: 42.0279
Manufacturer: Westfalia-Automotive GmbH
Introduction
This document provides installation instructions for the Westfalia tow bar (part number 42.0279) designed for the Isuzu D-Max vehicle, model year 2012 onwards.
Installation instructions are available in multiple languages, including Swedish (original), Czech, German, Danish, Spanish, French, Finnish, English, Greek, Hungarian, Italian, Norwegian, Dutch, Polish, and Russian.
Parts List
The following components are included in the kit:
| Item No. | Part Description | Quantity |
|---|---|---|
| 1 | Tow Bar Frame Assembly | 1x |
| 4 | Mounting Bracket (Left/Right) | 1x |
| 7 | Mounting Bracket (Left/Right) | 1x |
| 10 | FBA 11032 | 1x |
| 11 | FFJ 8373H | 1x |
| 12 | FFJ 8373V | 2x |
| 13 | FMS 4019 | 2x |
| 14 | FFJ 6375 | 2x |
| 15 | M12x40 (8.8) Bolt | 10x |
| 16 | M12x1.25x40 (8.8) Bolt | 6x |
| 17 | M10x30 Bolt | 4x |
| 18 | M8x30 Bolt | 2x |
| 19 | M6x20 Bolt | 2x |
| 20 | M12 Lock Washer | 4x |
| 21 | M8 Lock Washer | 2x |
| 22 | M6 Lock Washer | 2x |
| 23 | 13x24x2 Washer | 20x |
| 24 | 10.5x22x2 Washer | 4x |
| 25 | 8.4x16x1.5 Washer | 2x |
| 26 | 7x22x1.5 Washer | 2x |
| 27 | 12.2 Washer | 6x |
Note: Specific part numbers and descriptions may vary slightly based on the exact kit version.
Technical Specifications
Homologation: 55R-01 0229 / Ext. 01
D Value: 16.13 kN (This value is determined based on European Directive 94/20, defined as D = (T x C) / (T + C) x 0.00981, where T is the maximum permissible gross vehicle mass and C is the maximum permissible towing mass of the towing vehicle).
Vertical Load (S): 140 kg
Clearance Requirements: Specific clearance spaces must be ensured as per Appendix 7, Figures 25a and 25b of the ECE-R 55 regulations. These include angular and dimensional clearances relative to the vehicle's overall dimensions.
Torque Specifications:
- M16 bolts: 200 Nm
- M12 bolts: 83 Nm
- M10 bolts: 48 Nm
- M8 bolts: 24 Nm
- M6 bolts: 9.9 Nm
Safety and General Installation Instructions
Adherence to national guidelines regarding installation approval is mandatory.
Any alteration or modification to the tow bar is strictly prohibited and will void the type approval.
Before installation, remove any insulating material or underbody protection from the vehicle's contact surfaces where the tow bar will be mounted.
The tow bar is designed for towing trailers and carrying loads. Any other use is forbidden.
Parking Sensor Compatibility: Vehicles equipped with parking assistance systems may experience malfunctions after tow bar installation if components (e.g., tow ball, coupling ball) are within the sensor's detection range. Adjust the sensor range or disable the parking assistance system if necessary. For tow bars with removable or pivoting balls, malfunctions are unlikely when the ball is not in the operating position.
The tow bar is a safety-critical component and must only be installed by qualified technicians. Incorrect installation poses a severe accident risk. The Swedish text of this manual is binding.
Subject to change without notice.
Installation Steps
Follow these steps for proper installation:
Step 01: Access Rear Area
Access the rear underside of the Isuzu D-Max pickup truck, typically via the tailgate area.
Step 02: Position Frame Components
Place the main tow bar frame and the left/right side mounting brackets under the vehicle's rear chassis, aligning them with the designated attachment points.
Step 03: Attach Main Frame
Secure the main tow bar frame to the vehicle's chassis using the provided bolts and washers. Ensure correct alignment before tightening.
Step 04: Mount Brackets
Attach the smaller mounting brackets to the vehicle's frame using specific bolts such as M12x1.25x40, M6x20, M8x20, and M12x40, as indicated in the diagrams.
Step 05: Install Crossmember
Connect the main tow bar crossmember to the previously mounted brackets using M12x40 bolts.
Step 06: Attach Tow Ball and Torque
Mount the tow ball hitch assembly to the main crossmember. Tighten all bolts to the specified torque values:
- M16: 200 Nm
- M12: 83 Nm
- M10: 48 Nm
- M8: 24 Nm
- M6: 9.9 Nm
Initial Checks: After initial use (e.g., 0 km) and again after approximately 1000 km, check and retorque all critical fasteners.
Towing Capacity: Ensure compliance with vehicle and tow bar weight limits (e.g., 'x' and 'x+29kg' diagrams indicate load considerations).
Clearance Check: Verify that all required clearance spaces (greater than 49mm where specified) are maintained around the tow bar assembly.
Declaration of Correct Installation
This section is a declaration by the installer confirming that the tow bar has been installed correctly according to the manufacturer's specifications and attachment points. It also confirms that the vehicle user has been informed about the proper use and maintenance of the tow bar.
