GDW Tow Bar Installation for Fiat Stilo Wagon (2003 onwards)
GDW Reference: 1388
Product Overview
This document provides comprehensive fitting instructions and technical details for the GDW tow bar system designed for the Fiat Stilo Wagon, model years 2003 onwards. The tow bar is identified by GDW Reference 1388.
EEC Approval and Specifications
EEC Approval Number: e6*94/20*0381*00
Key technical specifications derived from the approval:
- D-value calculation: D = (max. kg / 9.81) * (max. kg / 9.81) / (max. kg + max. kg) * 0.00981 ≤ 8.00 kN
- S-value (Max. vertical load on ball): 60 kg
- Max. towing capacity: 1300 kg
Installation Instructions
- Remove the vehicle's bumper and permanently detach the buffer beam and plastic caps from the bodywork to ensure clear access to the chassis beam.
- Position the mounting pieces (-g) and (-h) at points (A) and (B) on the pre-drilled holes located on the outer and underside of the chassis beam. At point (B), insert mounting piece (-f) through the rear opening of the chassis beam. Insert the necessary bolts and washers but do not tighten them yet.
- Drill points (C) using a 10.5mm diameter drill bit. Unscrew the bolts at point (A) and insert mounting pieces (-i) and (-j) into the chassis beam via the rear openings. Ensure points (A) and (C) align correctly with the chassis beam drillings. Insert bolts but do not tighten.
- Place the tow bar between mounting pieces (-i) and (-j), aligning points (D) of the tow bar with the corresponding points on the mounting pieces. Insert the necessary bolts and washers, then tighten all fixings securely.
- Create a cut in the bumper according to the provided sketch. Slide the bumper over the tow bar until it is correctly positioned, then secure the bumper.
- Mount the ball (*) together with the socket holder (-p) and the safety shackle (-s). Ensure all these components are also tightened securely according to the specified torque values.
Component List
| Item Ref. | Description | Quantity | Attachment Points |
|---|---|---|---|
| 1388 | Tow bar | 1 | N/A |
| T45M004 | Ball mount | 1 | (*) |
| Bolts M12x65 | 2 | (*) | |
| Bolts M12x60 | 2 | (*) | |
| Nuts M12 | 4 | (*-*) | |
| T45 | Mounting tubes | 2 | (*) |
| T45 | Mounting pieces | 2 | (*-*) |
| -s | Safety shackle | 1 | (*) |
| P04 | Socket holder | 1 | (*) |
| Bolts M12x40 | 2 | (A) | |
| Washers M12 | 2 | (A) | |
| Bolts M10x40 | 4 | (B-C) | |
| Bolts M10x35 | 4 | (D) | |
| Washers M10 | 8 | (B-C-D) | |
| -f | Mounting piece | 2 | (B) |
| -g | Mounting piece | 1 | (A-B-C) |
| -h | Mounting piece | 1 | (A-B-C) |
| -i | Mounting piece | 1 | (A-C-D) |
| -j | Mounting piece | 1 | (A-C-D) |
All bolts and nuts used are quality 8.8.
Bumper Cutout Details
A specific section of the vehicle's bumper requires modification. The diagram illustrates the area to be cut, with labels indicating:
- 'B': The bumper itself.
- 'O': The lower rim of the bumper.
- 'M': The middle section of the bumper.
This refers to the hatched area that needs to be removed.
Technical Specifications and Torque Values
Torque Specifications for Bolts (Quality 8.8)
| Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|
| M6 | 10.8 | 1.1 |
| M8 | 25.5 | 2.60 |
| M10 | 52.0 | 5.30 |
| M12 | 88.3 | 9.0 |
| M14 | 137 | 14.0 |
Torque Specifications for Bolts (Quality 10.9)
| Bolt Size | Torque (Nm) | Torque (kgm) |
|---|---|---|
| M6 | 13.7 | 1.4 |
| M8 | 35.3 | 3.6 |
| M10 | 70.6 | 7.20 |
| M12 | 122.6 | 12.5 |
| M14 | 194 | 19.8 |
| M16 | 299.2 | 30.5 |
Clearance Requirements
All clearances must comply with Supplement VII, diagram 30 of guideline 94/20/EG. The diagrams show specific minimum and maximum dimensions and angles required for safe operation.
Important Notes and Warnings
- For the maximum permissible towing mass for your vehicle, please consult your vehicle dealer or owner's manual.
- Ensure any bitumen coating or anti-vibration material is removed from the designated mounting points before installation.
- Exercise caution during drilling to avoid damaging any brake lines, electrical wiring, or fuel lines.
