GDW Tow Bar Fitting and Usage Guide for Suzuki Jimny (09/98-)

Important Advice and Recommendations

General Fitting Advice

• Before fitting, inspect the tow bar for transport damage and verify it is the correct model for your vehicle.
• Carefully read and follow all mounting instructions provided.
• Present the tow bar under the vehicle before drilling to ensure correct positioning.
• When drilling holes, check for and avoid damaging any existing wiring or brake lines.
• Remove soundproofing or bitumen layers from drilled areas.
• Treat drilled holes and chassis contact points with an anti-corrosive product.
• If your vehicle has non-standard bumpers (e.g., sport versions, tuning kits), consult GDW technical service before installation.
• Note: The tow bar may be assembled for shipping; disassemble parts as needed for installation.

Guarantee and Maintenance

• To determine your vehicle's maximum towing weight, consult the Certificate of Conformity (COC) or your dealer. Do not exceed the tow bar's specified technical limits.
• The tow bar requires inspection after the first 1,000 km of use and at least annually.
• Inspection checklist:
  • Check and retighten all bolts as necessary.
  • Repair any paint damage.
  • Replace any components damaged due to accidents or collisions.
  • Lubricate internal parts of detachable systems.

Usage Guidelines

• If the towing ball obstructs the number plate or fog light, it must be removed when not in use. ❗

Technical Specifications

For maximum trailer weight, refer to your vehicle's Certificate of Conformity (COC) or contact your dealer.

D-Value: 7.00 kN (Calculated as: max towing weight [kg] * max towing weight [kg] * 0.00981 ≤ 7.00 kN)

S-Value (Vertical Load): 80 kg

Maximum Towing Weight: 1400 kg

Technical Clearance: Ensure compliance with Appendix VII, Diagram 25 (a,b) of Regulation No. 55 regarding required clearances.

Parts List

The tow bar kit (Ref. 2234) includes the following main components:

• 1 x Tow Bar Main Assembly (GDW REF. 2234)
• 1 x Tow Ball Neck (GDW REF. 944.L015)
• Brackets (GDW REF. 2, 3, 4, 5)
• Bolts (DIN931-M12 x 70, DIN933-M10x35)
• Nuts (DIN985-M12, DIN934-M10)
• Washers (DIN125-A10-140HV-ELVZ, DIN9021-M10-ELVZ)
• Spring Washers (DIN128A-M10)
• Tow Ball (GDW REF. 900.053)
• Locking Pin (GDW REF. PO7)

Note: Specific quantities for bolts, nuts, and washers are detailed in the fitting steps.

Fitting Instructions

Follow these steps carefully for installation. Refer to diagrams for visual guidance.

Step 1: Access Mounting Points

Locate and access the designated mounting points on the vehicle's chassis at the rear. [Tool: Socket 10]

Step 2: Prepare Mounting Points

Ensure the mounting points are clean and ready for installation. [Tool: Socket 10]

Step 3: Attach Main Frame

Position the main tow bar frame against the chassis mounting points. [Tool: Socket 10]

Step 4: Bumper Removal

Carefully remove the rear bumper. Arrows indicate the direction of removal. [Icon: Bumper removal]

Step 5: Mount Brackets

Attach the tow bar brackets to the vehicle chassis using the provided hardware (Parts 3, 4, 5, 7, 8, 9). Tighten to 54.0 Nm. [Tool: Socket 17]

Step 6: Attach Tow Bar Body

Connect the tow bar main body (Part 2) to the mounted brackets. Secure with hardware (Parts 5, 7, 8, 9). Tighten to 54.0 Nm. [Tool: Socket 17]

Step 7: Secure Main Frame

Ensure the main tow bar frame is correctly positioned and secured to the chassis. Use hardware (Parts 1, 5, 7, 8, 9). Tighten to 54.0 Nm. [Tool: Socket 17]

Step 8: Final Frame Checks

Perform final checks on the main frame attachment. Use hardware (Parts 5, 7, 8). Tighten to 54.0 Nm. [Tool: Socket 17]

Step 9: Attach Tow Ball Neck

Mount the tow ball neck (Part 2) to the tow bar assembly. Secure with hardware (Parts 5, 7, 9, 8). Tighten to 54.0 Nm. [Tool: Socket 17]

Step 10: Bumper Modification/Re-installation

If necessary, trim or modify the rear bumper to accommodate the tow bar. Ensure clearance of approximately 25-25mm and 45mm as indicated in diagrams.

Step 11: Final Tow Ball Assembly

Attach the tow ball (Part C) to the tow ball neck (Part A) using the provided bolts (B) and locking pin (D). Tighten the tow ball neck to 93.0 Nm.

• Tow Ball Neck: A (GDW REF. 944.L015)
• Bolts: B (DIN931-M12 x 70) x2
• Tow Ball: C (GDW REF. 900.053)
• Locking Pin: D (GDW REF. PO7)
• Nuts: DIN985-M12 x2

[Icon: Torque wrench 17, 93.0 Nm]

Optional Accessories

Optional accessories, such as alternative hitch systems (e.g., AFN), may be available. Consult GDW for details.