Westfalia Tow Bar Installation Guide for BMW 5 Series (F10/F11)

Product Overview and Specifications

This document provides installation instructions and technical information for the Westfalia tow bar, part number 303 397 600 001, designed for BMW 5 Series models (F10 and F11).

Key Specifications:

ECE-R 55 Compliance:

Installation must ensure adequate clearance as specified in Appendix 7, Figures 25a and 25b of the ECE-R 55 directive. This includes maintaining specific angles and distances relative to the vehicle's structure and ground.

Vehicle Weight Considerations:

When installing and using the tow bar, it is crucial to adhere to the vehicle's Gross Vehicle Weight (GVW) rating. Specific limits for towing and vertical load must be observed as per the vehicle's registration documents.

Important Warnings and Disclaimers

General Safety:

• This tow bar is a safety-critical component and must only be installed by qualified professionals.
• Improper installation can lead to serious accidents.
• Any modifications or alterations to the tow bar itself are strictly prohibited and will void the operating license/type approval.
• The German text of this manual is considered binding.
• Keep all fasteners tightened; re-torque after 1000 km.
• Ensure adequate clearance (minimum 49mm) around mounting points.

Vehicle Systems:

• If your vehicle is equipped with a parking assistance system (parking sensors), the tow bar may cause malfunctions if the ball or its components are within the sensor's detection range. Adjust the sensing range or disable the system if necessary. Removable or pivoting ball hitches may mitigate this issue when the ball is in the stowed position.
• Remove any insulating material or underbody protection from the vehicle's mounting surfaces before installation.

Complaints:

If you encounter any issues, contact your contract partner directly and provide the charge number found on the type plate. Complaints cannot be processed without this information.

Parts List

The following components are included in the kit:

• 1x Tow bar main assembly
• 1x Tow ball
• 1x Ball cap/cover
• 1x Electrical connector housing
• Fasteners:
  • 2x M12x80 (10.9) bolts
  • 4x M12x25-12 bolts
  • 3x 13x24x2.5 washers/spacers
  • 2x M12 nuts
  • 1x M8x30 (8.8) bolt
  • 1x 8.4x16x1.6 washer
  • 1x M8 nut

Installation Instructions

Follow these steps carefully for correct installation:

Preparation

• Step 1.1: Remove the rear bumper sections as indicated by arrows in the diagram.
• Step 1.2: Remove side bumper sections as indicated by arrows.
• Step 2.1 a): Identify the designated cut-out area 'a.1' on the vehicle's chassis. Remove the part labelled 'b.1'.
• Step 2.1 b): Detach part 'b.1' using appropriate tools, noting any clips that need to be released.
• Step 2.2 a): Identify the new cut-out area 'a.2' on the chassis and prepare to remove part 'b.2'.
• Step 2.2 b): Remove part 'b.2' from the vehicle.

Mounting the Tow Bar

• Step 3: Carefully insert the main tow bar assembly into the prepared mounting points on the vehicle chassis.
• Step 4: Secure the tow bar assembly (labelled '1') using two M12x25-42 bolts and two M12x25-45 bolts. Torque the M12x25-45 bolts to 95 Nm.
• Step 5: Secure another mounting point of the tow bar assembly (labelled '1') using one M8x30 bolt and one 8.4x16x1.6 washer. Torque the M8x30 bolt to 20 Nm.

Trim Modification and Refitting

• Step 6.1: With the tow bar assembly (1) mounted, prepare to refit or modify the plastic trim part labelled 'a.1'.
• Step 6.2 a): Modify the plastic trim part labelled 'a.2' as indicated in the diagram, which may involve cutting and removing clips.
• Step 6.2 b): Fit the modified trim part 'a.2' back into its position on the vehicle.
• Step 7.1 a): Cut the plastic trim part labelled 'b.1' according to the specified dimensions: 130mm length, 80mm width, with a radius of R20.
• Step 7.1 b): Fit the modified trim part 'b.1' onto the vehicle's rear.
• Step 7.2 a): Cut the plastic trim part labelled 'b.2' according to the specified dimensions: 100mm length, 80mm width, 40mm depth, with a radius of R10.
• Step 7.2 b): Fit the modified trim part 'b.2' onto the vehicle's rear.

Final Assembly

• Step 8.1: Re-fit the main rear bumper sections as indicated by the arrows.
• Step 8.2: Re-fit the side bumper sections as indicated by the arrows.
• Step 9: Attach the tow ball (labelled '2') to the tow bar assembly (1) using M12x80 bolts and 13x24x2.5 washers. Torque the M12x80 bolts to 95 Nm. Install the electrical connector housing (labelled '4') and the ball cap (labelled '3').

Post-Installation Check:

• Clearance Check: Ensure a minimum clearance of 49mm is maintained around the tow bar mounting points, as per ECE-R 55 regulations. A green checkmark indicates compliance, while a red cross indicates non-compliance.
• Service Interval: After the initial 1000 km of use, it is mandatory to re-torque all mounting fasteners. This is indicated by a '0km' symbol followed by a '+' and a '1000km' symbol with a wrench icon.
• Load Capacity: Adhere to specified towing and vertical load limits.

Declaration of Correct Installation

The manufacturer declares that the tow bar type 303 337 has been installed correctly according to the manufacturer's specifications and mounting points on the vehicle.

The user has been informed about the proper use and maintenance of the tow bar.