GDW Towbar for Alfa Romeo 159
Model: GDW Ref. 1577
Vehicle Compatibility: Alfa Romeo 159 PSW + STW (04/2006 - ....)
EEC Approval and Technical Specifications
EEC Approval Number: e6*94/20*0604*00
| Specification | Value |
|---|---|
| Max. Vertical Load (D) | 85 Kg |
| Max. Towing Mass | 1800 Kg |
| D-Value Calculation Reference | X * 0.00981 ≤ 10.00 KN |
Parts Composition and Torque Specifications
Parts List
| GDW Ref. | Description | Quantity | Notes |
|---|---|---|---|
| T43L001 | Towbar Arm | 1x | |
| 800.000 | Mounting Bracket | 1x | |
| P03 | Bracket Component | 1x | |
| - | Filling Tube (1) | 2x | |
| - | Counter Plate (2) | 2x | |
| - | Nut Piece (3) | 1x | |
| - | Tubes for Bumper (4) | 4x | |
| - | Counter Plate for Bumper (5) | 2x | |
| - | Filling Piece (6) | 1x | |
| - | Towing Ring (7) | 1x | |
| - | Socket Plate Holder | 1x | |
| GDW Ref. 1577 | Complete Towbar Assembly | 1x | |
| DIN 931 | Bolts M10x90, 8.8 | 2x | A, C |
| DIN 931 | Bolts M10x170, 8.8 | 4x | C |
| DIN 933 | Bolts M10x35, 8.8 | 2x | B |
| DIN 933 | Bolts M12x40, 8.8 | 4x | |
| DIN 128 | Washers A10-FSt | 8x | A-B-C |
| DIN 128 | Washers A12-FSt | 4x | |
| DIN 934 | Nuts M10, 8.8 | 6x | A-C |
Torque Specifications (Nm)
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 | 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 | 19.8 |
| M16 | 299.2 | 30.5 |
Installation Instructions
Step 1: Prepare Vehicle
Remove the bumper, rear exhaust damper, and heat shield. If the vehicle has a dual exhaust, remove both dampers. Permanently remove the mounting bolts located at the side of the spare wheel tray (refer to Photo 2). Treat cut surfaces with a rust protection agent.
Step 2: Position and Drill Chassis
Position the towbar with reference point X on the indicated stop (refer to Photo 1). Align points (A) and (B) against the underside of the chassis beam, centering the towbar on the vehicle. Drill point (A) through the chassis beam into the trunk space. Drill point (B) through the chassis beam. Enlarge the drilling for point (A) in the trunk space to Ø21mm. Insert filling tube (1) into the chassis beam. Position counter plate (2) onto the filling tube and insert bolts loosely. At point (B), insert nut piece (3) through the large opening in the chassis beam. Place filling piece (6) between the chassis beam and the towbar. Insert bolts and tighten firmly, following torque specifications.
Step 3: Prepare Bumper and Drill
Drill points (C) through the bottom of the towbar tube. These must pass completely through the bumper beam. Detach the bumper beam again. Insert tubes (4) between the two drillings in the bumper beam. Install bolts and counter plate (5). Re-attach the bumper beam to the vehicle, ensuring bolts align with the towbar tube drillings. Tighten all fasteners firmly.
Step 4: Modify Heat Shield and Re-install Exhaust
Make an incision in the heat shield (refer to Photo 3) to allow re-assembly on the vehicle. Re-hang the exhaust damper on its rubber mounts.
Step 5: Modify Bumper and Re-mount
Make an incision in the underside of the bumper according to Drawing 1. Make a second incision in the plastic part of the bumper according to Drawing 2. Re-mount the bumper onto the vehicle.
Step 6: Assemble Ball Assembly
Assemble the tow ball, safety eye, and socket plate holder onto the towbar.
Bumper Disassembly Details
- Remove 2x3 screws from the wheel wells.
- Remove 4 screws from the underside of the bumper (2 central, 2 near rear wheels).
- Remove 2x1 screw from under the rear light units.
- Unclip the sides of the bumper and pull it backward. Note: The bumper is clipped under the rear lights and at the trunk entrance.
Visual Aids Descriptions
Photo 1: Vehicle Underside
Illustration showing the underside of the Alfa Romeo 159 rear chassis, indicating mounting points for the towbar.
Photo 2: Drilling Point Detail
Close-up view showing a drilled hole (point A) in the chassis beam, with a bolt and filling tube inserted.
Photo 3: Modified Heat Shield
Image of the vehicle's heat shield with a cut made to accommodate the towbar installation.
Drawing 1: Bumper Cut-out
Diagram showing the rear bumper with a hatched area indicating the required cut-out. Labels: "B" = bumper, "O" = lower rim of bumper, "M" = middle of bumper.
Drawing 2: Plastic Bumper Cut-out
Diagram showing the plastic part of the bumper with a hatched area indicating the required cut-out. Labels: "B" = bumper, "O" = lower rim of bumper, "M" = middle of bumper.
Clearance Diagram
Technical diagram illustrating required clearance dimensions (min/max angles and distances) for the towbar coupling, conforming to guideline 94/20/EG, Appendix VII, Diagram 30. This section is presented in Dutch, French, English, and German.
Important Notes and Recommendations
General Advice
- Before starting, inspect the towbar for transport damage and verify its reference number for the vehicle.
- Read and follow the fitting instructions precisely.
- Present the towbar under the vehicle before drilling to check alignment.
- When drilling, ensure no existing wiring, brake lines, or fuel lines are damaged.
- Remove any soundproofing or bitumen coating from the mounting areas. Treat drilled holes and bodywork with an anti-corrosive paint.
- If the vehicle has non-standard bumpers (special series, sport versions, tuning parts), consult GDW technical service to confirm compatibility.
Warranty and Maintenance
- Do not exceed the indicated maximum towing mass, "D", and "S" values.
- The towbar must be checked after the first 1,000 km of use and at least once a year.
- Check and retighten all bolt connections as necessary.
- Repair any paint damage.
- Replace any components damaged by accidents or collisions.
- Grease internal parts of detachable towbar systems.
- If the towbar ball obstructs the number plate or fog light, it must be removed when not in use.
Usage Recommendations
- Consult your vehicle dealer or owner's manual for the maximum permissible towing mass.
- If the tow ball covers the number plate or fog light, it must be removed when not in use.
