Westfalia Tow Bar Installation and Operating Instructions

Product Overview

This document provides comprehensive installation and operating instructions for Westfalia tow bars designed for Mercedes Benz C-Klasse vehicles, specifically models W 203 and S 203. It covers two versions: Version A (313 166) for C-Klasse Limousine and Kombi T-Modell without height control, and Version B (313 168) for C-Klasse Kombi T-Modell with height control.

Westfalia-Automotive GmbH
Part Number: 313 166 691 111 - 02/08 - 001

Approval Details: Approval No: e13 B00-0892, Type: 313166/A; 313166/B, Part No: [See above], D-Value: 9.1 kN, Vertical Load: 75 kg, Coupling Class: A50-X.

Parts List

Important Safety and Installation Notes

Vehicle Manual: ? Always consult the vehicle's operating manual before commencing installation.

National Regulations: Adhere to all national guidelines concerning the approval of vehicle extensions and installations.

Prohibited Modifications: Any alteration or modification to the tow bar is strictly forbidden and will void the vehicle's type approval and operating permit.

Surface Preparation: Remove any insulating compound or underseal from the vehicle's chassis contact surfaces where the tow bar will be mounted.

Intended Use: The tow bar is designed for towing trailers equipped with ball couplings and for use with approved load carriers (e.g., bike racks) that mount onto the coupling ball. Any other use is prohibited.

Parking Assistance Systems: Vehicles equipped with parking assistance systems (e.g., PDC) may experience malfunctions after tow bar installation. This can occur if parts of the tow bar (ball bar, coupling ball) are within the sensors' detection range. If this happens, the detection range may need to be adjusted, or the parking assistance system deactivated. For tow bars with detachable or swiveling ball bars, malfunctions are generally not expected if the ball bar is removed from its operating position.

Clearance Requirements: Ensure specified clearance dimensions are met as per Appendix VII, Diagram 30 of Directive 94/20/EC. Key clearances include minimum distances from the vehicle body and maximum angles for the tow ball mount.

Weight Limits:

• Maximum Vertical Load (S): 75 kg
• D-Value: 9.1 kN
• Maximum Towing Capacity: Refer to the vehicle's registration document.

Note on Gross Vehicle Weight: The specified weight ratings apply at the vehicle's permissible gross weight.

General Warning: Subject to alteration. Always follow the specific instructions provided.

Installation Steps

Step 1: Access the rear of the vehicle by opening the trunk lid. ⬆️

Step 2: Remove interior trim panels in the trunk area. For W 203 and S 203 models, remove side panels or covers on both the left (LH) and right (RH) sides to access the chassis mounting points. ➡️

Step 3: Further removal of side trim panels on LH and RH sides as needed.

Step 4: On S 203 models, remove a storage compartment or bracket located on the right (RH) side. ➡️

Step 5: Access electrical connectors or mounting points, potentially a control unit or junction box, on the left (LH) side (S 203). ➡️

Step 6: Locate the mounting points on the right (RH) side of the vehicle chassis. Bolts are typically pre-installed or visible.

Step 7: Remove clips or fasteners from the rear bumper area on the left (LH) side. ➡️

Step 8: Carefully remove the rear bumper cover by pulling it downwards and away from the vehicle. ⬇️

Step 9: Remove any undertray or protective cover located beneath the rear bumper area. ⬇️

Step 10: Prepare the bumper cover for the tow bar installation. This may involve cutting or modifying specific areas according to the tow bar design. Screws and clips are indicated for this process.

Step 11: Attach the main tow bar mounting brackets (labeled '1') to the vehicle chassis. Ensure any wiring or connectors are managed. Secure the brackets using bolts (e.g., 7x 13x24x2.5) and nuts (e.g., 2x M10 (8)).

Step 12: Fully secure the mounting brackets to the chassis.

Step 13: Mount the main tow bar arm (labeled '3') to the chassis brackets. Use bolts such as M10x30 and 10.5x30x3. Tighten to a torque of M10 → 55Nm.

Step 14: Re-install the undertray or protective cover removed in Step 9.

Step 15: Attach additional mounting brackets (labeled '4' and '5') to the vehicle chassis using bolts like M10x30 and 10.5x30x3.

Step 16: Mount the main tow bar structure (labeled '1') to the chassis. Use bolts such as 13x24x2.5 and nuts M12x1.5x40. Tighten to a torque of M12x1.5 → 95Nm. ⬆️

Step 17: On the left side (LH), attach the tow ball neck assembly. This includes bracket '8' and tow ball neck '10'. Use bolts M10x60, M10x30, 10.5x30x3, and 10.5x34x4. Tighten to specified torques: M10 (10) → 55Nm and M10 (8) → 40Nm. ?

Step 18: Repeat Step 17 for the right side (RH) of the vehicle.

Step 19: Perform a final tightening of a specific bolt on the right (RH) side of the tow bar structure. Torque specification: M10 → 55Nm. ?

Step 20: Attach the tow ball (labeled '2') to the tow ball neck (labeled '1'). Use bolts 13x24x2.5 and nuts M12x75. Tighten to a torque of M12 → 95Nm. ?

Step 21: Re-install interior trim panels on the left (LH) side of the trunk area (S 203). ↩️

Step 22: Re-install the storage compartment or bracket on the right (RH) side (S 203). ↩️

Step 23: Re-install side trim panels on both LH and RH sides of the trunk (S 203). ↩️

Step 24: Re-install bumper components on the W 203 model. ↩️

Step 25: Re-install the trunk floor trim. ↩️

Technical Specifications and Clearance

Clearance Diagram: The diagram illustrates required clearance zones around the tow bar and coupling ball, adhering to Directive 94/20/EC. It specifies minimum distances (e.g., min. 32mm, min. 55mm, min. 65mm) and maximum angles (e.g., max. 45°, max. 30°) relative to the vehicle's structure and the tow ball mount.

Weight Ratings:

• Maximum Vertical Load (S): 75 kg
• D-Value: 9.1 kN
• Maximum Towing Capacity: Refer to the vehicle's registration document.

Note on Gross Vehicle Weight: The specified weight ratings apply at the vehicle's permissible gross weight.

Declaration of Correct Installation

The manufacturer declares that the tow bar has been installed correctly according to the manufacturer's specifications and attachment points. The user has been informed about the use and maintenance of the tow bar.