GDW Tow Bar Installation Manual
For Peugeot 5008 (01/2010 onwards), Citroën C4 Picasso (09/2007 onwards), Citroën C4 Grand Picasso (10/2006 onwards)
Manufacturer: GDW NV
Contact: GDW@GDWTOWBARS.COM | TEL +32 (0)56 604212 | FAX +32 (0)56 600193
Document Revision: N° 000 | Date: 17-05-2010 | Reference: 1814
General Advice and Recommendations
This section consolidates important advice from multiple languages regarding the installation and use of GDW tow bars.
General Fitting Instructions
- Before starting installation, inspect the tow bar for any transport damage and verify it is the correct reference for your vehicle.
- Carefully read and follow all instructions in the fitting manual.
- Present the tow bar under the vehicle before drilling or making any permanent attachments to ensure correct alignment.
- If drilling is required, ensure no electrical wiring, brake lines, or other critical components are present.
- Remove any soundproofing or bitumen coating from drilled areas. Treat drilled holes and chassis parts with an anti-corrosion product.
- If the vehicle is equipped with non-standard bumpers (e.g., special series, sport versions, tuning parts), consult GDW technical service before proceeding to ensure compatibility.
- The tow bar is typically shipped partially assembled for storage; disassemble parts as needed for installation.
Guarantee and Maintenance
- To determine the correct towing weight capacity for your vehicle, refer to the Certificate of Conformity (COC) or contact your vehicle dealer. Do not exceed the tow bar's technical specifications.
- The tow bar must be checked after the first 1,000 km of use and at least once annually. Checks should include:
- Verifying and retightening all bolt connections as necessary.
- Repairing any damage to the paint finish.
- Replacing any components damaged due to an accident or collision.
- Greasing the internal parts of detachable tow bar systems.
Usage Guidelines
- If the tow ball obstructs the license plate or fog light when not in use, it is mandatory to remove the tow ball.
- Ensure the tow ball is always clean and greased. If using a coupling with a stabiliser, follow the stabiliser manufacturer's instructions.
- Regularly measure the tow ball diameter; it must not be less than 49 mm.
- GDW NV cannot be held responsible for incorrect installation or improper use of the tow bar.
Technical Specifications
The following formulas and specifications are provided for calculating towing capacity and ensuring correct installation.
Towing Capacity Formulas
D-Value Calculation:
D = (MAX KG * MAX KG * 0.00981) ≤ 9.80 kN
Where MAX KG refers to the maximum permissible weight of the vehicle and the trailer.
S-Value (Vertical Load):
S = 75 KG (Maximum permissible vertical load for the tow bar)
The maximum towing weight for the specified vehicles is 1700 KG.
Torque Specifications for Bolts
| Bolt Size | Strength Class 8.8 | Strength Class 10.9 | Strength Class 12.9 |
|---|---|---|---|
| M6 | 10.4 Nm | 15.5 Nm | 18.0 Nm |
| M8 | 25.0 Nm | 37.0 Nm | 43.0 Nm |
| M10 | 51.0 Nm | 75.0 Nm | 87.0 Nm |
| M12 | 87.0 Nm | 130.0 Nm | 150.0 Nm |
| M14 | 140.0 Nm | 205.0 Nm | 240.0 Nm |
| M16 | 215.0 Nm | 310. Nm | 370.0 Nm |
Required Tools
The following tools are typically required for installation:
- Wrenches: 10mm, 16mm, 17mm, 19mm
- Screwdrivers: TX20, TX30, TX15
- Sockets: 10mm, TXE14
- Torque Wrench
- Possibly other standard automotive tools.
Parts List
The following components are included in the tow bar kit:
| Item No. | GDW Ref. | Description | Quantity |
|---|---|---|---|
| 1 | 1814 | Main Tow Bar Frame | 1x |
| 2 | 200304 | Left Tow Bar Bracket | 1x |
| 3 | 200305 | Right Tow Bar Bracket | 1x |
| 4 | 2 | Tow Bar Arm/Hitch Receiver | 1x |
| 5 | 3 | Tow Ball Mount | 1x |
| 6 | P04 | Tow Ball | 1x |
| 7 | T45L035 | Hitch Pin | 1x |
| 8 | 800008 | M10 Bolt | 2x |
| 9 | 800011 | Ø21.3 L=11.7 Washer | 2x |
| 10 | 800000 | M12 Bolt | 1x |
| 11 | DIN125-A10-140HVELVZ | M10 Washer | 14x |
| 12 | DIN128A-M10 | M10 Lock Washer | 14x |
| 13 | DIN931-M10x45 | M10x45 Bolt | 6x |
| 14 | DIN933-M10x35 | M10x35 Bolt | 4x |
| 15 | DIN934-M10 | M10 Nut | 8x |
| 16 | DIN931-M12x70 | M12x70 Bolt | 4x |
| 17 | DIN985-M12 | M12 Lock Nut | 4x |
Installation Procedure
The following steps detail the installation process for each vehicle model. Always refer to the diagrams for visual guidance.
Peugeot 5008 (01/2010 onwards)
- Step 1: Remove the rear taillights. Arrows indicate pulling them outwards. Use a TX30 screwdriver.
- Step 2: Remove the rear bumper cover. Arrows indicate pulling the cover downwards and outwards.
- Step 3: Detach the bumper cover from the sides. Use a TX30 screwdriver and a 10mm socket.
- Step 4: Remove fixings for the inner wheel arch liner. Use a 10mm socket.
- Step 5: Remove the original bumper beam. Use a TX30 screwdriver and a 10mm socket. Disconnect any [parking sensor system] (PDC) wiring if applicable.
- Step 6: Attach the main tow bar frame to the vehicle's chassis mounting points. Use a TXE14 wrench.
- Step 7: Attach the tow bar side brackets to the chassis. Use a 16mm wrench.
- Step 8: Reinstall the bumper cover. A visual inspection is indicated by an eye icon, followed by [step 23].
Citroën C4 Picasso (09/2007 onwards)
- Step 1: Remove the rear taillights. Arrows indicate pulling them outwards. Use a TX20 screwdriver.
- Step 2: Remove the rear bumper cover. Arrows indicate pulling the cover downwards and outwards.
- Step 3: Detach the bumper cover from the sides. Use a TX20 screwdriver and a 10mm socket.
- Step 4: Remove fixings for the inner wheel arch liner. Use a TX30 socket.
- Step 5: Remove the original bumper beam. Use a TX30 screwdriver and a 10mm socket. Disconnect any [parking sensor system] (PDC) wiring if applicable.
- Step 6: Attach the main tow bar frame to the vehicle's chassis mounting points. Use TX30 and TX20 screwdrivers.
- Step 7: Attach the tow bar side brackets to the chassis. Use a 16mm wrench.
- Step 8: Reinstall the bumper cover. A visual inspection is indicated by an eye icon, followed by [step 23].
Citroën C4 Grand Picasso (10/2006 onwards)
- Step 1: Remove the rear taillights. Arrows indicate pulling them outwards. Use a TX15 screwdriver.
- Step 2: Remove the rear bumper cover. Arrows indicate pulling the cover downwards and outwards.
- Step 3: Detach the bumper cover from the sides. Use a TX30 socket.
- Step 4: Remove fixings for the inner wheel arch liner. Use a TX30 screwdriver. Disconnect any [parking sensor system] (PDC) wiring if applicable.
- Step 5: Remove the original bumper beam. Use a 16mm wrench.
- Step 6: Reinstall the bumper cover. A visual inspection is indicated by an eye icon, followed by [step 23].
Tow Bar Assembly and Mounting
- Step 1: Mount the main tow bar frame to the vehicle's chassis. Use the specified bolts (items 4, 5, 6) and a 17mm wrench.
- Step 2: Attach the tow bar side brackets to the chassis. For Peugeot 5008 and Citroën C4 Picasso, use bolts (items 4, 5, 6, 7, 8) and a 17mm wrench. For Citroën C4 Grand Picasso, use bolts (items 4, 5, 6, 7, 8) and a 17mm wrench.
- Step 3: Attach the tow ball mechanism to the main tow bar frame. Use a 16mm wrench.
- Step 4: Secure the tow ball mechanism to the frame. For Peugeot 5008 and Citroën C4 Grand Picasso, use bolts (items 2, 4, 5, 8) and a 17mm wrench, connecting to specific points indicated. For Citroën C4 Picasso, use bolts (items 4, 5, 8) and a 17mm wrench.
- Step 5: Attach the tow ball mechanism to the frame for Citroën C4 Picasso. Use bolts (items 4, 5, 8) and a 17mm wrench.
- Step 6: Attach the tow ball mechanism to the frame for Citroën C4 Picasso. Use bolts (items 4, 5, 8) and a 17mm wrench.
- Step 7: Mount the tow ball hitch to the tow bar frame. Use the specified components (B, C, E, F, 9) and a 19mm wrench. Note the required dimensions: 40mm, 50mm, R32, R20, 65mm clearance. Ensure bolts are tightened to specified torque values.
- Step 10: Attach the tow ball to the hitch. Use the hitch pin (item 7, T45L035) and secure with components D, E, F.
AFN Options
Alternative tow ball systems (AFN) may be available. Consult GDW for details.
Final Placement
After installation, place the owner's manual in the designated location within the vehicle's interior.
Clearance Requirements
The following diagram illustrates clearance requirements as specified by directive 94/20/EG, Appendix VII, illustration 30. These clearances must be maintained.
Diagram Description: The diagram shows side and front views of a tow bar installation, indicating minimum and maximum angles and distances (e.g., max. 45°, min. 140mm, min. 75mm, max. R14.5, max. R40). It also shows the relationship between vehicle and trailer weights.
Multilingual Text from Diagram:
- Dutch: De tussenruimte conform supplement VII, afbeelding 30 van de richtlijn 94/20/EG moet in acht worden genomen.
- French: La zone de dégagement doit être garantie conformément à l'annexe VII, illustration 30 de la directive 94/20/CE.
- English: The clearance specified in appendix VII, diagram 30 of guideline 94/20/EG must be guaranteed.
- German: Der Freiraum nach Anhang VII, Abbildung 30 der Richtlinie 94/20/EG ist zu gewährleisten.
- Spanish: Revisar la imagen 30 del suplemento VII según la directiva 94/20EG
- Danish: Frirummet skal overholdes iht. bilag VII, fig. 30 i direktiv 94/20/EF.
Vehicle Weight Information:
- Dutch: Bij toelaatbaar totaal gewicht van het voertuig
- French: Pour poids total en charge autorisé du véhicule
- English: At laden weight of the vehicle
- German: Bei zulässigem Gesamtgewicht des Fahrzeuges
- Spanish: Peso total admisible del vehículo
- Danish: Ved tilladt samlet vægt for køretøjet
