PCT Automotive Fitting Instruction

Components

Bolt Pack

Fitting Procedure

1. Lift boot floor covering and remove spare wheel and jack assembly. Remove rear light clusters (Two plastic screws on each cluster accessed from inside boot). Remove bumper (3 torx screws on lower edge, 2 screws in each wheelarch, 1 screw at each bumper tip (loosening of wheel arch liner may facilitate removal), 1 plastic screw/clip behind each light cluster, pull bumper tips outwards before pulling rearward, disconnect wiring for reversing sensors if fitted).
2. Remove and discard the impact beam bolted to rear panel. Remove chassis end blanking plates. Remove foil tape covering the mounting positions at (K) & (L). Loosen exhaust hanger bolt which protrudes into chassis on left hand side.
3. Insert side arms (E) & (F) into vehicle chassis and loosely attach at the forward points (from inside boot) using bolts (L) with heavy duty washers (M) under the bolt heads.
4. Insert reinforcing plates (C) & (D) into the ends of vehicle chassis and align with holes in side arms (E) & (F). Attach to side arms (E) & (F) using bolts (K) at the forward positions with heavy duty washers (M) under the bolt heads. Note: Access to forward position (K) on the left hand side is achieved by removing the blanking plug and/or air vent on the outside of the vehicle.
5. The chassis openings must be sealed to prevent water ingress. (Use previously removed chassis end blanking plates (cut to fit around side arms), or other suitable method). Also, replace nuts onto bumper beam mounting threads and seal around.
6. Attach towbar (A) to reinforcing plates (C) & (D) and side arms (E) and (F) using bolts (J). Use spacer plate (G) between reinforcing plate (C) & towbar (A) on the left hand side. Note: The towbar is positioned just below the plastic bumper support – if additional clearance is required, trim the support to suit. Tighten bolts. Retighten exhaust mounting bolt.
7. Replace air vent and blanking plug. Replace bumper, rear lights, spare wheel, jack assembly and floor covering.
8. Attach towbar neck (B) & electrical mounting bracket (EP) to towbar (A) using bolts (I). The electrical mounting bracket carries type approval information required by law and must always be fitted as shown. Tighten bolts ensuring the faceplate remains vertical.

When fitting this towbar to a vehicle requiring a type approved towbar, a type approved towball with 'D' and 'S' values which match or exceed those of the towbar must be fitted. The horizontal distance from the towbar faceplate to the centre of the ball must not exceed 76mm. The vertical distance from the centre of the towball holes to the centre of the ball must not exceed 75mm.

Also for use with PCT Automotive swan neck coupling (Part code ZC1519).

Torque Settings

Tighten All Bolts

• ISO Coarse Pitch: M8=29Nm, M10=58Nm, M12=102Nm, M16=252Nm
• ISO Fine Pitch: M8=31Nm, M10=61Nm, M12=111Nm

The vehicle manufacturer's specification for the trailer weight and nose load limits must be observed.

Fitting Diagram

[Diagram showing towbar components and their placement on the vehicle chassis, with labels corresponding to the component list: A (Towbar), B (Towbar Neck), C/D (Reinforcing Plates), E/F (Side Arms), G (Spacer Plate), EP (Electrical Mounting Bracket), and various bolts (H, J, K, L, M). Arrows indicate the order of assembly and connection points.]

Important Product Information & Guarantee

Thank you for purchasing a PCT Automotive product. Please read the following information carefully before fitting or using your PCT Automotive product.

Guarantee

PCT Automotive will, free of charge, either repair or at its option replace defective goods where defects appear:

• If the goods are a towbar manufactured by PCT Automotive, during the economic lifetime of the vehicle it was first fitted to.
• In the case of all other products manufactured by PCT Automotive, within 3 years following the date of your order.

Provided that (in each case) such defects shall be found to PCT Automotive's reasonable satisfaction to have arisen substantially from faulty design, workmanship or materials and have not arisen by reason of a failure to follow instructions, any modification, misuse, neglect or interference with the installation, any damage or abuse to the goods or vehicle by impact or vandalism or by a failure to carry out reasonable inspection, maintenance and/or adjustment.

The above guarantee is subject to PCT Automotive's standard terms and conditions of sale, a copy of which is available upon request from their offices.

Towing Limits

PCT Automotive towbars are designed for towing up to the vehicle manufacturer's maximum recommended trailer weight and nose load limits for your model. Towing with gross weights above that recommended at any time will invalidate the guarantee and cancel any liability for damage. Towing a twin axle trailer, towing over rough ground or using a bicycle/motorcycle carrier, etc., exerts extreme loads on to a towbar and extra care should be taken in these situations not to exceed the vehicle manufacturer's maximum recommended limits.

Product Identification Mark

Your product carries a product identification mark. This mark carries important product and batch code information and if the product is type approved, it also carries the type approval details which are required by law. Under no circumstances should this mark be defaced, removed or damaged.

Installation, Inspection, Maintenance and Adjustment

General Installation

• Products should only be fitted by competent persons.
• Read the product fitting instructions carefully and check all components are included in the fitting kit before commencing installation.
• Check vehicle for corrosion and/or accident damage. Towbars should not be fitted to any vehicle suffering from corrosion or accident damage or which is not in a roadworthy condition.
• Clean off all road dirt, underseal and sound deadening mastic where parts are to fit to ensure correct seating of all components.
• Bumper cut information is given as a guide only. Variations in models may occur, therefore the fitter should always check that the bumper cut is necessary and of the correct size and shape before commencing with the cut.
• All drilling swarf should be removed from the vehicle and all holes drilled in the vehicle should be treated with an appropriate rust inhibitor.
• Do not fully tighten bolts before towbar is completely fitted unless instructed to do so in the fitting instruction, this will allow some variances to be overcome before final tightening of bolts.

Paint & Corrosion

PCT Automotive towbars undergo a phosphate chemical pre-treatment prior to an epoxy/polyester powder coat finish being applied. For long-lasting good looks and in order to prevent corrosion, the towbar should be regularly inspected for paint damage and wherever necessary re-painted in an appropriate finishing paint or underseal. The vehicle should also be regularly checked for any corrosion that could affect the towbar installation. Towbars should not be used on any vehicle suffering from corrosion that could affect the towbar installation.

Bolts

All towbar fixing bolts should be checked initially after the first 300 towing miles and then every 3,000 towing miles or to coincide with the vehicle manufacturer's recommended service intervals, whichever is the sooner, and should be tightened using an appropriate torque wrench to the settings specified in the towbar fitting instruction.

Electrical Installation, Test/Commissioning and Maintenance

Failure to comply with the following instructions may cause damage to the towing vehicle's wiring loom and/or towing electrics installation.

• Where displacement tap connectors (e.g., Scotchloks) are the preferred method of connection, always use the correct colour-coded tap connector for the size of cable to which it is to be connected. PCT Automotive's manufactured relays with integral cables should be connected using red tap connectors (0.5mm² to 1mm² conductor cross-sectional area).
• After installation of the 12N/12S sockets, prior to testing, a water displacement agent (e.g., WD40) should be applied into the rear connection void through the water drain hole at the bottom of the sockets and also into the front pins under the socket flap. This socket maintenance should be carried out at least twice a year in the spring and autumn.
• The towing electrics test procedure must be undertaken with the engine running. If any of the towing relays fail to function correctly, with the engine running and no other vehicle electrical systems turned on, check that the voltage across the vehicle's battery is between 13V and 14V approx. If this voltage is not correct, check the condition of the vehicle's battery/alternator.
• Always ensure that the trailer/caravan/lighting board's own electrical systems are installed and functioning correctly before coupling to the vehicle's 12N/12S sockets.
• Every six months (spring and autumn recommended) the battery and alternator of the vehicle should be checked to determine correct electrical functioning. All connections of the electrical installation, including the earth, should be checked for mechanical soundness and electrical quality. Plugs, sockets, relays and fixings should be checked for water ingress, mechanical soundness, electrical quality and general wear and tear.

Please complete the following information to validate the guarantee and for future reference.

Vehicle Owner Name & Address:

Vehicle Make & Model:

Fitter Name & Address:

Vehicle Registration Number:

Date Towbar Fitted:

If you have any comments or suggestions about the PCT Automotive product fitted to your vehicle, please address them to PCT Automotive, Holbrook Industrial Estate, Sheffield S20 3GH or email techsupport@pctautomotive.com. Your comments will help PCT Automotive in their aim to continually upgrade their products to meet the high standards expected by their customers.