General Information

Installation Time: Approx. 60 Minutes

Towbar Capacity

Vehicle: HYUNDAI TUCSON TL & TLe SERIES

Part Number: 03157RW

Max Towing Braked: 1600 kg

Max Towing Unbraked: 750 kg

Max Static Ball Load: 140 kg

Warnings

1. Do not drill, cut, weld, or otherwise modify the towbar.
2. If using electric welding on a motor vehicle, always check that the vehicle is not equipped with electronic engine or instrument management equipment. Failure to do so could destroy any onboard computers. If in doubt, check with the vehicle's manufacturer.
3. If the Tow Ball Mount (TBM) is used in an inverted position, the tow ball may make contact with the rear tailgate when lowered, which could cause damage.

General Installation Advice

1. Ensure all hardware items are included; refer to the assembly diagram.
2. It is recommended that the instructions are read through and completely understood before making any attempt to fit this product.
3. Be wary of any changes to vehicle designs or other accessories that may conflict with the installation of this product.
4. Before drilling, ensure that the area is clear of fuel, electrical, and other components.
5. All holes drilled into the body panels shall have all burrs and swarf removed, then coated with a suitable rust preventative paint.
6. The high tensile fasteners supplied with this product were used to achieve the specified rating. If replacement is required, ensure that fasteners of the same rating and quality are used. Contact an authorized Hayman Reese dealer if further information is required.
7. Ensure that all hardware is fastened to the torque list below and check fasteners on a regular basis.
8. The towbar load rating sticker provided with this product shall be conspicuously located on the inside rear end of the driver's door.
9. Hayman Reese recommends that you check your tow ball to ensure that it complies with the Australian standards AS 4177.2.
10. NOTE: It is advised to remove your LUG or TBM when not actually towing so as to produce a clear view of the vehicle's registration plate if obscured, and to also provide maximum available departure angle.
11. Pull Pin must be fitted in the down position.

Towbar Maintenance and Care

Hayman Reese recommends that bolt torques, as listed below, are routinely and regularly inspected and checked for correct tension. Replace any worn or defective parts. We recommend removing Tow Ball Mounts (TBM's, tongues or lugs) when not being used for any considerable length of time. To avoid injury, when not towing, it is suggested that the tongue, Pull Pin, and R-clip are removed and stored in a safe, clean, and dry place, away from excessive moisture. Hitch Pull Pins and spring "R" clips should be regularly checked for proper installation. Replace any worn or defective parts.

Recommended Assembly Torque

For towing capacity details, please refer to the vehicle owner's manual or the manufacturer. Overloading can void your warranties.

Parts List

Installation Steps

Step 1

Remove the plastic trim cover adjacent to the tail light assembly. Repeat for the opposite side of the vehicle.

Step 2

Remove 2 screws securing the taillights to the vehicle. Remove the tail light assembly. Repeat for the opposite side of the vehicle.

Step 3

Remove 2 push rivets from the taillight cavity. Repeat for the opposite side of the vehicle.

Step 4

Remove 4 screws located within the rear wheel arch. Repeat for the opposite side of the vehicle.

Step 5

Remove 2 screws adjacent to the chassis rail, securing the rear impact beam to the rear panel. Repeat for the opposite side of the vehicle.

Step 6

Remove 3 push rivets from under the vehicle behind the rear wheel arch and 1 push rivet from within the rear wheel arch. Repeat for the opposite side of the vehicle.

Step 7

Remove the plastic undertray from behind the rear wheel arch. Repeat for the opposite side of the vehicle.

Step 8

Carefully unclip and remove the rear bumper, disconnecting any applicable wiring looms.

Step 9

Remove 3 push rivets securing the impact beam bumper tabs to the bumper.

Step 10

Remove 2 clips securing the top of the impact beam to the bumper.

Step 11

Where applicable, release the smart key antenna from the impact beam.

Step 12

Detach wiring from the impact beam and remove and discard the impact beam from the rear bumper.

Step 13

Loosely secure the sidearm to the side face of the chassis rail using 2x M10 screws, complete with 1 flat washer per screw. Repeat for the opposite side of the vehicle.

Step 14

Loosely secure the sidearm to the underside of the chassis rail using 2x M10 screws, complete with 1 flat washer per screw. Repeat for the opposite side of the vehicle.

Step 15

Loosely secure the welded assembly to the sidearms using 4x M12 screws per side arm. For 2 of the screws, use 2 flat washers and 1 M12 nut per pair. For the remaining 2 screws, use 1 flat washer per screw.

Step 16

Tighten all screws to the torque listed on page 2 of this document.

Step 17

Where required, secure the smart key antenna brackets to the holes in the top of the towbar using Tek Screws.

Step 18

Secure the bumper tab brackets in the holes on the rear face of the towbar using Tek screws.

Step 19

Identify the centre of the bumper and create a bumper cut as per the diagram. The diagram indicates a cut is made in the center of the rear bumper to accommodate the towbar assembly.

Step 20

Mark out and drill 2 holes, each 5mm in diameter and 69mm apart, on the bumper skin to support the plug bracket. Feed the bracket threads through the drilled holes prior to reinstalling the bumper.

Step 21

Refit the rear bumper by following steps 1 to 4 and 6 to 8 in reverse order.

Step 22

Where applicable, secure the smart key antenna to the smart key antenna brackets.

Step 23

Secure loose wiring to the towbar using cable ties.

General Information

Tail Harness Length Required: 1200mm

RPA Over ride Switch Part No: 04848 (if fitted)

Wiring Loom Installation Time: Approx. 50 minutes

Important: Due to possible vehicle variations, always confirm any noted vehicle colour wires with a multi-meter to ensure the correct function is identified before soldering or scotch locking. For vehicle wires denoted with two colours (e.g., RED/GREEN), the first colour will always be the main wire colour while the second colour is the thinner trace colour on the wire.

Installation Steps

Step 1

Fold down the rear passenger seats.

Step 2

Remove the luggage compartment floor, tools, jack, and jack bracket.

Step 3

Remove the rear trim and its two fasteners.

Step 4

Remove the four fasteners from each side of the luggage compartment trims and then dislodge the luggage compartment trims.

Step 5

Remove the rear passenger RHS kick trim.

Step 6

Remove the driver's door sill trim.

Step 7

Remove the bonnet handle and then remove the driver's kick panel trim.

Step 8

On the RHS of the luggage compartment, locate the RHS rear quarter existing grommet hole and drill out to 30mm. Apply rust inhibitor after drilling (not supplied). If the grommet hole is occupied, pick a nearby location on the vehicle sheet metal to drill through.

Step 9

From the vehicle interior, retrieve the vehicle RHS tail light connector.

Step 10

Route the trailer patch (Part No: 201365-WL) connectors to the retrieved RHS tail light connector and connect to the mating trailer patch connector.

Step 11

Route the remaining trailer patch connector through the vehicle grommet hole until the trailer patch grommet is seated correctly.

Step 12

Route the trailer patch LHS branch towards the LHS vehicle tail light area and then connect the trailer patch connector to the mating vehicle harness tail light connector.

Step 13

Pierce a small hole into the vehicle grommet and route the trailer patch reverse terminal into the vehicle. The diagram shows routing of wires from the exterior to the interior through the grommet.

Step 14

Following the table below, connect the ezy-tap to the corresponding vehicle wire, then connect the trailer patch terminal to the ezy-tap.

Step 15

At the rear exterior of the vehicle, mount the tail harness socket to the towbar mounting bracket using M4 fasteners (not supplied).

Step 16

Route the tail harness (tail length: 1200mm) across the RHS and up into the drilled out hole. Adjust the trailer patch harness grommet so that it is seated correctly and cable tie in place.

Step 17

Connect the tail harness 8-way connector to the Trailer Patch 8-way mating connector.

Step 18

Secure the trailer patch ground ring terminal to the vehicle stud (nut not supplied).

Step 19

Route the trailer patch 1-way connector along the vehicle harness, all the way towards the driver's fuse panel area.

Step 20

Remove the indicated vehicle 30A fuse. Insert the vehicle 30A fuse and the supplied 20A fuse into the add-a-fuse harness. Connect the trailer patch 1-way connector to the add-a-fuse harness. Insert the add-a-fuse harness into the previously removed fuse location. Ensure the add-a-fuse harness is oriented as shown. The diagram illustrates fuse removal, add-a-fuse installation, and correct orientation.

Step 21

For RPA over ride function, locate the 13-way connector at the LHS lower rear exterior of the vehicle.

Step 22

Locate the ORANGE wire from the indicated pin location of the connector.

Step 23

Cut the connector ORANGE wire.

Step 24

Patch RPA Over ride (Part No: 04848) in between the cut ORANGE wire.

Step 25

Seal and waterproof the connection appropriately after patching.

Step 26

Refit tail lights.

Step 27

Test the Trailer Harness function using a light board or multi-meter.

Step 28

Secure all harnesses using cable ties (not supplied).

Step 29

Re-fit removed parts and secure all fasteners, ensuring there are no squeaks or rattles.

Step 30

Place the instructions in the glove box after fitment.

Maintenance and Inspection

NOTE: Routine maintenance and inspection of the towbar & SMART PIN is required. Regularly inspect for wear and check the tightness of the SMART PIN NUT. Follow instructions below to retighten the nut when necessary.

*Do not tow with your vehicle if the R CLIP or the SMART PIN NUT is loose or missing. Replacement parts are available from your Hayman Reese Distributor.

Installation Steps

Step 1

Insert the Trailer Ball Mount (TBM) into the towbar HITCHBOX, aligning the hole in the TBM SHANK with the hole in the HITCHBOX. The diagram shows the TBM being inserted into the hitchbox, aligning holes.

Step 2

Insert the SMART PIN through the hole in the HITCHBOX and the hole in the TBM SHANK. Ensure the LOCATORS are inserted into the NOTCHES in the HITCHBOX. The diagram shows the Smart Pin being inserted, with locators aligning with notches in the hitchbox.

Step 3

Screw the SMART PIN NUT onto the SMART PIN. Tighten the SMART PIN NUT until finger tight, ensuring the TBM is restrained from movement.

Step 4

Tighten the SMART PIN NUT by turning the nut a further 1/8th of a turn in the clockwise direction using a 24mm spanner. The diagram shows a spanner tightening the nut.

Step 5

Install the SMART PIN R CLIP through the hole on the SMART PIN. The diagram shows the completed assembly with the R-clip in place.