GDW Towbar Installation Guide for Kia Rio (2005-Present)
Vehicle Model: Kia Rio
Model Years: 09/2005 - ....
GDW Reference: 1538
EEC Approval Number: e6*94/20*0557*00
Technical Specifications
| Parameter | Value |
|---|---|
| D Value | X * 0.00981 ≤ 7.00 KN |
| S Value (Max. towing weight) | 50 Kg |
| Max. towing weight | 1200 Kg |
Note: For the maximum permissible towing mass, consult your vehicle's dealer or owner's manual.
Towbar Assembly Diagram
Diagram illustrating the GDW towbar assembly for the Kia Rio. Key components include mounting plates (labeled A, B, 1, 2), the main towbar frame (labeled C, D, E, F), and the ball mount assembly (labeled I).
Parts List
| GDW Reference | Quantity | Description |
|---|---|---|
| T43M002 | 1x | Mounting plate component |
| 800.000 | 1x | Mounting plate component |
| P03 | 1x | Mounting plate component |
| 112158 | 1x | Mounting bracket |
| 112159 | 1x | Mounting bracket |
| 1538 | 1x | Towbar main assembly |
| 700000 | 1x | Plastic bumper piece |
| 700001 | 1x | Plastic bumper piece |
| 700002 | 2x | Bolt set |
| 700003 | 2x | Bolt set |
| DIN961-M12x1,25x35 - 8.8 | 4x | Bolt (A-B) |
| DIN128-A12-FSt | 8x | Washer (C-D) |
| DIN128-A10-FSt | 6x | Washer (C-D) |
| Rondsels Ø24x13x2,5mm | 2x | Washer (B) |
| DIN933-M12x40 - 8.8 | 4x | Bolt (C-D) |
| DIN933-M10x30 - 8.8 | 6x | Bolt (C-D) |
| DIN934-M10 - 8.8 | 6x | Nut (C-D) |
Bolt Torque Specifications
Quality 8.8
| 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
| 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
Disassemble the bumper and permanently remove the metal buffer beam at the back of the vehicle. Retain the plastic bumper piece to re-assemble it on the towbar afterwards. Adjust wiring of the fog lamp as indicated on Photo 1 and in the text below.
Fog Lamp Wiring Adjustment: Cut the 2 wires of the fog lamp inside the trunk that are fixed against the back plate of the coachwork (see Photo 1). Loosen the rubber cap in the middle and remove the wiring from the vehicle. Attach the provided sockets on both sides. Assemble the lamp holder onto the fog lamp in the bumper.
Position the mounting plates, 1 on the left and 2 on the right, with points (A) and (B) against the exterior side of the chassis beams, aligning with the provided screw-thread holes. Insert the bolts, washers, and security washers, but do not fasten tightly yet.
Place the towbar against the back plate, aligning points (C) with the provided drilling and points (D) with points (D) of the already placed pieces (1) and (2). Insert the bolts and fasten all components securely according to the torque specifications.
Attach the plastic bumper piece onto points (E) of the towbar.
Make an incision in the lower side of the bumper according to Figure 1. Assemble the bumper onto the vehicle and fix it at the bottom to points (F) of the towbar using the original rivets.
Assemble the ball mount together with the safety shackle and the socket holder. Insert the bolts and fasten them securely according to the torque specifications.
Bumper Disassembly:
- Disassemble the rear light units (remove 2 screws and pull lights sideways).
- Remove 2x2 plastic plugs under the rear light units.
- Remove 4 plastic plugs at the trunk entrance.
- Remove 2x3 screws at the wheel cases.
- Remove 2x1 plastic plug at the bottom of the bumper near the wheel case.
Diagrams and Visuals
Photo 1: Fog Lamp Wiring
Photograph showing the interior of the vehicle's trunk. It depicts the fog lamp wiring harness, with a pair of wires marked by a [scissors symbol] indicating the point for cutting.
Figure 1: Bumper Cut-out
Diagram showing the required bumper cut-out. The hatched area indicates the section to be removed from the bumper. Labels define 'B' as the bumper, 'O' as the lower rim of the bumper, and 'M' as the middle of the bumper. Dimensions are provided.
Clearance Specifications Diagram
Technical diagram detailing the clearance specifications for the towbar installation, in accordance with guideline 94/20/EG. It shows required clearances and dimensions relevant to the vehicle's laden weight.
Important Advice and General Instructions
To Be Kept in the Vehicle
Fitting:
- Before starting the installation, ensure the towbar has not been damaged during transport and is the correct reference for the vehicle.
- Read the fitting instructions carefully and follow them precisely.
- Present the towbar under the car first to check alignment and fit.
- When drilling holes, check carefully to ensure no wires (brake lines, electrical wiring, fuel lines) or pipes are damaged.
- Remove any soundproofing material or bitumen coating from the mounting areas.
- Treat drilled holes and carrosserie parts with an anti-corrosive product.
- If the vehicle is equipped with non-standard bumpers (special series, sport versions, tuning parts, etc.), contact GDW technical service before proceeding with the installation.
Guarantee:
- Do not exceed the indicated towing weight, 'D', and 'S' values.
- The towbar must be checked after the first 1,000 km of use and at least once per year.
- Check all bolt connections and retighten if necessary.
- Repair any damage to the paint finish.
- If the towbar is damaged due to an accident or extreme load, it must be replaced.
- Grease the internal parts of detachable towbar systems.
Use:
- If the towing ball covers the number plate or the fog light, it must be removed when no trailer is used.
