Product Information
This document provides detailed installation instructions for the GDW tow bar, reference number 1267, designed for the Kia Rio vehicle models manufactured between 2000 and 2003.
Vehicle Compatibility:
Kia Rio (Models 2000 - 2003)
EEC Approval:
e6*94/20*0264*00
Technical Specifications:
- D-Value: D = [max kg] x [max kg] x 0.00981 ≤ 6.40 kN
- Max. Towing Capacity (s/): 50 kg
- Max. Vehicle Weight (Max.): 1100 kg
Manufacturer:
GDW nv
Hoogmolenwegel 23, B-8790 Waregem
Website: www.gdwtowbars.com
Installation Instructions
Please follow these steps carefully for correct installation. Ensure all parts are present before starting.
- Disassembly: Remove the rear light units and the bumper. Take out the interior trim and floor covering from the trunk. Permanently remove the metal buffer beam from the bumper.
- Chassis Mounting: Slide the mounting pieces (-h) and (-i) through the rear openings into the chassis beams. Ensure points (A) and (B) align with the drillings where the buffer beam was attached. If point (C) is covered by bitumen coating, remove it at the fastening location. Attach the mounting plates (-l) at points (A) and (B) and insert the bolts. At point (B), insert the tube (-m) into the chassis beam via the large opening at the rear. Insert the necessary bolts, washers, and nuts at points (A), (B), and (C) but do not tighten them fully yet.
- Tow Bar Attachment: Position the tow bar between the two mounting pieces (-h) and (-i). Ensure points (D) and (D') of the tow bar align with the corresponding points on the mounting pieces. Insert the necessary bolts, washers, and nuts, and then tighten everything firmly according to the specified torque values.
-
Vehicle Specific Modifications (2000-2002 Models):
- Make an incision in the underside of the bumper as shown in Sketch 1.
- Fasten the synthetic buffer beam to the tow bar using tape and then re-assemble the bumper in its original position.
- Assemble the 2 bumper supports (-j) and (-k) using points (F) on the bumper's corner fixings (where it was attached to the buffer beam) and point (G) on the provided drilling in the vehicle's bodywork. Insert and tighten the bolts securely.
-
Vehicle Specific Modifications (2003 onwards Models):
- Make an incision in the underside of the bumper as shown in Sketch 2. Adjust the buffer beam to align with the tow bar's corner fixings (refer to Photo 1).
- Attach the 2 bumper supports (-n) with points (O) to the tow bar. Insert bolts, washers, and nuts but do not tighten them yet (refer to Photo 2).
- Attach the mounting pieces (-r) and (-q) to the center support of the tow bar (refer to Photo 3). Insert and securely tighten bolts, washers, and nuts.
- Attach the corner supports (-s) and (-t) with point (U) to the provided drillings in the vehicle's bodywork (refer to Photo 4). Insert bolts but do not tighten them yet.
- Replace the bumper and then firmly tighten the bolts at points (O) and (U).
- Final Assembly: Re-assemble the rear light units. Mount the tow ball (*) along with the security shackle and the socket holder, and tighten them according to the specified torque values.
Parts List (Composition)
| Item | Description | Quantity | Reference |
|---|---|---|---|
| 1 | Tow bar | 1 | Ref. 1267 |
| 2 | Tow ball | 1 | T45H000 (*) |
| 3 | Bolts M12x65 | 2 | (*) |
| 4 | Bolts M12x60 | 2 | (*) |
| 5 | Security nuts M12 | 4 | (*) |
| 6 | Mounting shells T45 | 2 | (*) |
| 7 | Tubes T45 | 2 | (*) |
| 8 | Security shackle | 1 | (-v) (*) |
| 9 | Bolts M12x35 | 4 | (D-D') |
| 10 | Security washers M12 | 4 | (D-D') |
| 11 | Nuts M12 | 2 | (D') |
| 12 | Bolts M10x35 | 4 | (A-C) |
| 13 | Bolts M10x80 | 2 | (B) |
| 14 | Security washers M10 | 6 | (A-B-C) |
| 15 | Nuts M10 | 2 | (B) |
| 16 | Washers 40x35x12x4 | 4 | (B-C) |
| 17 | Bolts M8x25 | 6 | (G-O-U-W) |
| 18 | Security washers M8 | 6 | (G-O-U-W) |
| 19 | Nuts M8 | 6 | (G-O-U-W) |
| 20 | Washers ø25x8.4x2mm | 2 | (G-U) |
| 21 | Mounting tubes (-m) | 2 | (B) |
| 22 | Mounting plates (-l) | 2 | (A-B) |
| 23 | Mounting piece (-j) and mounting piece (-k) | 1 | (G-F) |
| 24 | Mounting piece (-h) and mounting piece (-i) | 1 | (A-B-C-D-D') |
| 25 | Mounting pieces (-n) | 2 | (O-P) |
| 26 | Mounting piece (-s) and mounting piece (-t) | 1 | (U-V) |
| 27 | Mounting piece (-q) | 1 | (W) |
| 28 | Mounting piece (-r) | 1 | (W) |
| 29 | Socket holder (-w) | 1 | (*) |
Technical Data & Notes
Bolt and Nut Quality:
All bolts and nuts used in this installation are quality 8.8 or 10.9.
Torque Specifications:
Quality 8.8 Bolts:
| 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 | 137.0 | 14.0 |
| M16 | 211.0 | 21.5 |
Quality 10.9 Bolts:
| 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 | 194.0 | 19.8 |
| M16 | 299.2 | 30.5 |
Important Notes:
- For the maximum permissible towing mass your vehicle can handle, please consult your vehicle's owner's manual or contact your dealer.
- Remove any bitumen coating or anti-drumming material from the mounting areas before installation.
- Exercise caution when drilling into the vehicle body. Ensure that brake lines, electrical wiring, or fuel lines are not damaged.
Diagrams and Sketches
Diagram 1: Exploded View of Tow Bar Assembly
Diagram showing the exploded view of the GDW tow bar assembly (Ref. 1267) for the Kia Rio, with various components labeled with letters (A-W) corresponding to the parts list.
Sketch 1: Bumper Modification for 2000-2002 Models
Sketch 1 illustrating the required cut-out area on the underside of the bumper for Kia Rio models 2000-2002. Shows dimensions and labels 'B' (bumper), 'O' (lower bumper rim), and 'M' (bumper center).
Sketch 2: Bumper Modification for 2003+ Models
Sketch 2 illustrating the required cut-out area on the underside of the bumper for Kia Rio models from 2003 onwards. Shows dimensions and labels 'B' (bumper), 'O' (lower bumper rim), and 'M' (bumper center).
Photo 1: Bumper Adjustment
Photo 1 showing the adjustment of the buffer beam on the bumper for models from 2003 onwards, aligning it with the tow bar corner fixings.
Photo 2: Bumper Support Attachment
Photo 2 showing the attachment of bumper supports (-n) with points (O) to the tow bar, with bolts, washers, and nuts inserted loosely.
Photo 3: Center Mounting Piece Attachment
Photo 3 showing the attachment of mounting pieces (-r) and (-q) to the center support of the tow bar, with bolts, washers, and nuts being secured.
Photo 4: Corner Support and Ball Assembly
Photo 4 showing the attachment of corner supports (-s) and (-t) with point (U) to the vehicle body, and the final assembly of the tow ball (*) with the security shackle (-v) and socket holder.
