GDW Tow Bar Installation Guide

Important Information & Advice

Before starting the installation, ensure the tow bar has not been damaged during transport and that it is the correct reference for the vehicle. Consult and follow all instructions in this manual meticulously.

General Fitting Advice:

• Present the towbar under the vehicle before commencing the actual fitting.
• If drilling is required, carefully check for any existing wiring (electrical, braking, etc.) to avoid damage. Remove any soundproofing or bitumen layers from the drilling area. Treat drilled holes and bodywork parts with an anti-corrosive product.
• For vehicles equipped with non-standard bumpers (e.g., special series, sport versions, tuning parts), it is imperative to contact GDW's technical service to confirm compatibility and any necessary modifications.
• The towbar supplied is often assembled for storage purposes; ensure all parts are disassembled before installation.

Guarantee & Maintenance:

• To determine your vehicle's maximum towing weight, refer to the Certificate of Conformity (COC) or consult your dealer. Do not exceed the towbar's specified technical limits.
• The towbar must be checked after the first 1,000 km of use and at least once annually. This includes:
  • Checking all bolt connections and retightening them as necessary.
  • Repairing any damage to the paint finish.
  • Replacing any components that have been damaged due to accidents or impacts.
  • Greasing the internal parts of detachable towbar systems.
• If the tow ball obstructs the license plate or the fog light, it is mandatory to remove the ball when the trailer is not connected.

Technical Specifications & Parts

Vehicle Compatibility: Kia Stonic (09/2017-)

GDW Reference: 2254

Towing Weight Calculation:

To determine the maximum towing weight (D-value) and maximum vertical load (S-value) for your vehicle, consult your vehicle's Certificate of Conformity (COC) or your dealer. The formulas are:

• D = (max kg) x (max kg) x 0.00981 ≤ 6.95 kN
• S = (max kg) + (max kg) = 80 kg (example) = 1200 kg (example)

Parts List:

The following components are typically included:

• 1 x GDW Ref. 2254 (Main Tow Bar Frame)
• 1 x 944.M000 (Tow Ball)
• 2 x GDW Ref. 900.008 (Tow Ball Socket Housing)
• 2 x GDW Ref. 900.011 (Ø 21.3 X 11.7 - likely washers or bushes)
• 2 x DIN931-M12 X 70 (Bolts)
• 2 x DIN985-M12 (Lock Nuts)
• 4 x DIN9021-M10-ELVZ (Washers)
• 5 x DIN125-A10-140HV-ELVZ (Washers)
• 5 x DIN933-M10×40 (Bolts)
• 1 x DIN934-M10 (Nut)
• 2 x DIN933-M8X30 (Bolts)
• 2 x DIN9021-M8-ELVZ (Washers)
• 2 x DIN128A-M8 (Spring Washers)
• 2 x DIN934-M8 (Nuts)
• GDW Ref. PO4 (-P)
• GDW Ref. 900.053 (-S)
• Tools: Torque wrenches (e.g., 10, 12, 13, 17, 19), Screwdriver (PH2).

Fitting Instructions

Follow these steps carefully for correct installation:

1. Step 1-2: Remove the vehicle's rear light clusters. Arrows indicate the direction of removal for the light units.
2. Step 3: Access the designated mounting points on the vehicle's chassis. The diagram shows the underside of the rear of the car, highlighting access areas.
3. Step 4: Remove any undertray components or bumper reinforcements necessary to access the mounting points. Arrows indicate parts to be removed.
4. Step 5: Carefully remove the vehicle's rear bumper cover. An arrow shows the bumper cover being pulled away from the vehicle.
5. Step 6: Remove the main bumper structure. An arrow indicates the bumper being detached from the vehicle.
6. Step 7: Remove the exhaust heat shield if it obstructs the tow bar installation. An arrow points to the heat shield for removal.
7. Step 8: Attach the main tow bar chassis brackets to the vehicle's frame. Use the specified bolts, nuts, and washers (e.g., parts 3, 4, 6, 8, 9, 10, 11).
8. Step 9: Connect the vehicle's electrical wiring harness to the tow bar's wiring system. An arrow shows the connector being plugged in.
9. Step 10: Position and attach the main tow bar frame to the previously installed chassis brackets. Secure using the appropriate bolts, nuts, and washers (e.g., parts 1, 3, 4, 5, 6, 7, 8, 9, 10, 11).
10. Step 11: Secure all newly attached tow bar components.
11. Step 12: Tighten the specified bolts to a torque of 54.0 Nm using a torque wrench (e.g., tool 17).
12. Step 13: Tighten further specified bolts to a torque of 54.0 Nm.
13. Step 14: Reattach the vehicle's rear bumper cover. An arrow shows the cover being placed back onto the vehicle.
14. Step 15: For vehicles requiring bumper modification, identify the areas to be cut on the bumper cover. Shaded areas on the diagram indicate the cutting zones.
15. Step 16: Measure and mark the cut lines on the bumper cover according to the specified dimensions (e.g., 40mm, 40mm, 35mm).
16. Step 17: Carefully cut the bumper cover along the marked lines to accommodate the tow bar.
17. Step 18: Reattach the modified bumper cover to the vehicle, ensuring it fits correctly around the tow bar components.
18. Step 19: Install the tow ball mounting bracket onto the tow bar frame. An arrow indicates the bracket's position.
19. Step 20: Attach the tow ball assembly to the mounting bracket.
20. Step 21: Reinstall the vehicle's rear bumper. An arrow shows the bumper being fitted back into place.
21. Step 22: Connect the trailer socket wiring. Ensure the connection is secure and tighten any associated bolts to 27.3 Nm.
22. Step 23: Connect the trailer socket wiring and associated components. Tighten bolts to 27.3 Nm.
23. Step 24: Install the vehicle's control unit (e.g., trailer module). The diagram shows placement and dimensions (50mm, 140mm) for mounting.
24. Step 25: Reinstall the vehicle's rear light clusters. Arrows indicate the units being pushed back into their positions.
25. Step 26: Attach the tow ball assembly to the tow bar frame. Use the specified hardware (e.g., parts A, B, C, D, -S, -P) and tighten to 93.0 Nm.
26. Step 27: Attach the tow ball assembly to the tow bar frame. Use the specified hardware (e.g., parts A, B, C) and tighten to 93.0 Nm. The AFN section mentions optional accessories.

Clearance and Weight Regulations

Clearance Requirements:

The required clearance must be guaranteed according to regulation nr. 55, appendix VII, diagram 25 (a,b). The diagram illustrates specific angles and dimensions (e.g., minimum 32mm, maximum 100mm, maximum 250mm, maximum 65°, maximum 45°, maximum 30°, maximum 15°) that must be maintained for proper operation and safety.

Vehicle Weight Limits:

Adherence to permissible total vehicle weight, authorized total laden weight, and admissible total vehicle weight is crucial. Always refer to your vehicle's documentation for these specifications.