GDW Tow Bar Installation Guide
For Mitsubishi Carisma (1995-1998) and Volvo V+S 40 (2001-...)
GDW Reference: 0904
General Information & Approval
This document provides fitting instructions for the GDW tow bar, reference 0904, designed for the Mitsubishi Carisma and Volvo V+S 40 vehicles.
EEC Approval
EEC Approval Number: e4*94/20*0424*00
The D-Value calculation is provided as: D = (max kg * max kg) / (max kg + max kg) * 0.00981 ≤ 8.50 kN
Maximum towing weight (s/ Max.): 75 kg
Maximum vertical load (Max.): 1400 kg
Installation Instructions
Please follow these steps carefully for correct installation. It is recommended to consult a professional if you are unsure.
Step 1: Bumper Modification and Preparation
Loosen the rear bumper in the middle and make an incision according to the following instructions:
- For Mitsubishi Carisma: Make an incision following the provided sketch. This involves cutting a specific hatched area of the bumper to accommodate the tow bar. The diagram indicates dimensions for this cut, approximately 60mm, 80mm, and 40mm in relation to specific points.
- For Volvo V+S 40: Make an incision in the middle of the bumper, measuring 50mm wide and 25mm high, starting from the lower edge.
Disassemble the exhaust system and the heat shield from the rear of the vehicle.
Step 2: Mounting the Tow Bar
Place the tow bar assembly against the vehicle's chassis. Align the mounting points labeled (A), (C), and (F) with the left sides of the chassis beams. Ensure points (B) align with the underside of the chassis. All these points should correspond with pre-threaded holes in the chassis.
Position the mounting piece (-h) over the chassis beam. Ensure the holes in the mounting piece align with tow bar point (F) and the pre-threaded hole on the exterior side of the chassis beam (E).
Insert all necessary bolts and washers and tighten them according to the specified torque values.
Step 3: Attaching the Towing Eye
Align point (D) with the opening in the towing eye.
Place a washer (Ø 45x13x7mm) between the towing eye and the tow bar. Place another washer on the outer side of the towing eye.
Insert the bolt, washers, and nut at point (D) and hand-tighten them for now.
Step 4: Final Assembly and Tightening
Assemble the main tow bar components (indicated by *) together with the socket holder (-p) and the security shackle (-s).
Now, securely tighten all points, including points (*) and (D), according to the specified torque values.
Step 5: Reassembly
Replace the heat shield and the exhaust system in their original positions and secure the exhaust.
Parts List (Composition)
| Item | Description | Quantity | Notes |
|---|---|---|---|
| 1 | Tow bar reference 0904 | 1 | |
| 2 | Ball post T45M002 | 1 | |
| 3 | Security shackle (-s) | 1 | (*) |
| 4 | Socket holder (-p) | 1 | (*) |
| 5 | Bolts M12x70 - DIN931 | 2 | (*) |
| 6 | Bolts M12x60 - DIN931 | 2 | (*) |
| 7 | Security nuts M12 | 4 | (*) |
| 8 | Mounting tubes T45 | 2 | (*) |
| 9 | Mounting shells T45 | 2 | (*) |
| 10 | Bolt M12x55 - DIN 933 | 1 | (D) |
| 11 | Security washer M12 | 1 | (D) |
| 12 | Nut M12 | 1 | (D) |
| 13 | Bolts M10x1.25x30 | 6 | (A-B-C-E) |
| 14 | Bolt M10x1.25x40 | 1 | (F) |
| 15 | Security washers M10 | 7 | (A-B-C-E-F) |
| 16 | Washers 40x35x12x4 | 5 | (B-C-F-E) |
| 17 | Mounting piece (-h) | 1 | (E-F) |
| 18 | Washers Ø45x13x7mm | 2 | (D) |
Technical Notes & Safety
- Bolt & Nut Quality: All bolts and nuts used are quality 8.8, unless otherwise specified.
- Towing Mass: For the maximum permissible towing mass for your vehicle, please consult your vehicle dealer or owner's manual.
- Surface Preparation: Remove any bitumen coating or sound deadening material from the fastening points on the vehicle chassis before installation.
- Drilling Caution: When drilling into the vehicle chassis, exercise extreme caution to avoid damaging any brake lines, electrical wiring, or fuel lines.
