GDW Towbar for Toyota Corolla Break (2002-)

Product Overview

This document provides installation instructions and technical specifications for the GDW towbar (Ref. 1342) designed for the Toyota Corolla Break model from 2002 onwards. The towbar is manufactured to high quality standards and includes all necessary components for fitting.

Technical Specifications

Assembly Diagram Description

The towbar assembly consists of several parts that connect to the vehicle's chassis and bumper. Key components include the main towbar hitch, mounting pieces (labeled 'g', 'h', 'i'), a ball hitch, and various bolts, nuts, and washers. The diagram shows an exploded view, illustrating how these parts fit together and attach to specific points (labeled A, B, C, D, E, F, Y, *) on the vehicle's frame and bumper structure.

Key Components and Attachment Points (as per diagrams and composition lists):

• Towbar Hitch (Ref. 1342)
• Ball Hitch (T43J001 / T43J006)
• Mounting Piece (g) - Attaches to the right side chassis beam.
• Mounting Piece (h) - Reinforcement strips.
• Mounting Piece (i) - Slides into the chassis beam.
• Various bolts (M6, M8, M10, M12, M12x1.25x35), nuts (M8, M12), and washers (security washers, standard washers) are used for assembly.
• Attachment points on the vehicle are indicated by labels such as A, A', B, B', C, D, E, F, F', Y, and *.

Bumper Cut-out Guide

A specific section of the vehicle's rear bumper needs to be cut to accommodate the towbar. The diagram indicates a hatched area that must be removed. The labels 'B' (bumper), 'O' (lower rim of bumper), and 'M' (middle of the bumper) help identify the precise cutting line. Dimensions provided are 40mm and 150mm, suggesting specific measurements for the cut.

Installation Instructions

Follow these steps carefully for proper installation. Ensure all bolts are tightened firmly only after all parts are in place, unless otherwise specified.

1. Remove the rear bumper and detach the exhaust from its rubber mounts. Remove the heat shield and the rear buffer, including its supports. Permanently remove the vehicle's original towing rings.
2. Attach mounting piece (g) to the right side of the vehicle's chassis beam. Align points (A) with the provided screw-thread holes and point (B') with its designated hole. Slide mounting piece (i) into the chassis beam through the rear opening until it aligns with the hole at point (B'). Insert bolts and washers, but do not tighten yet.
3. Position the towbar hitch so that points (F) and (F') align with the corresponding points on mounting piece (g). On the left side of the vehicle, align points (A) with the provided screw-thread holes and point (B) with its designated hole. Slide mounting piece (i) into the chassis beam through the rear opening until it aligns with the hole at point (B'). Insert bolts, washers, and nuts, but do not tighten yet.
4. Install the protection strips (h). Align points (D) of these strips with the towbar hitch. Points (E) of the strips should align with pre-welded bolts on the vehicle's sides. Insert all remaining bolts, washers, and nuts, and then tighten everything firmly.
5. Make a cut in the rear bumper according to the provided diagram and re-install the bumper.
6. Install the ball hitch (*) and the Y-bracket (Y), and tighten them firmly.

Note: Before drilling, check for and avoid damaging brake lines, electrical wiring, or fuel lines. Remove any bitumen coating or anti-vibration material from the fastening points.

Parts Composition

The following parts are included in the kit:

• 1 x Towbar Hitch (Ref. 1342)
• 1 x Ball Hitch (T43J001 / T43J006)
• 6 x Bolts M12x35
• 10 x Security Washers M12
• 3 x Nuts M12
• 4 x Bolts M12x1.25x35
• 6 x Washers 40x35x12x4
• 2 x Bolts M10x35
• 2 x Security Washers M10
• 1 x Bolt M6x25
• 1 x Security Washer M6
• 1 x Washer Ø18x6.5x1.5
• 2 x Bolts M8x30
• 2 x Security Washers M8
• 4 x Nuts M8
• 2 x Mounting Pieces (i)
• 2 x Mounting Pieces (h)
• 1 x Mounting Piece (g)

All bolts and nuts are quality 8.8, unless otherwise specified.

Torque Specifications

Recommended torque values for bolts and nuts:

Quality 8.8

Quality 10.9

Important Notes

• For the maximum permissible towing mass for your vehicle, consult your car dealer or owner's manual.
• Ensure the installation area is free of bitumen coating or anti-vibration material.
• Exercise caution when drilling to avoid damaging brake lines, electrical wiring, or fuel lines.