GDW Tow Bar Installation Guide
Suzuki Alto 5-door (2003-...)
GDW Reference: 1398
EEC Approval Number: e6*94/20*0393*00
Installation Steps
- Disassemble the inner lining of the trunk. Permanently remove the towing eye located in the middle, at the bottom of the vehicle. Remove the two rubber caps found at the end of the chassis beams.
- Make an incision in the middle of the lower rear bumper according to the diagram. The diagram indicates a cut in the hatched area of the bumper's lower rim (approx. 60mm width, 20mm depth) at the center.
- Position the tow bar (marked 'A') onto the freed screw-thread holes where the towing eye was attached. Insert bolts loosely.
- Drill holes (ø10.5mm) perpendicularly through the chassis beam into the trunk, after removing the caps. From underneath, insert the supplied small tubes into the chassis beam. Inside the trunk, place the counter plates (7 and 8) over the drilled holes, ensuring the recess in the counter plate aligns with the mounting point of the floor covering. Insert bolts through these holes and loosely attach the side plates (5 and 6) with their points (C) onto these bolts. Align these plates with the chassis beams and drill points (B) and (D) through into the trunk (ø10.5mm). Enlarge these holes to ø16mm and insert the small tubes through the trunk into the chassis beams. Place the counter plates on top and insert the bolts without tightening.
- Align points (E) and (E') of the side plates with the drillings in the tow bar. Insert the bolts but do not tighten yet (refer to torque specifications).
- Mount the ball hitch or the pedestal of the detachable ball hitch, along with the safety shackle and socket plate. Tighten all components firmly.
Parts Composition
| Part Name | Quantity | Reference/Notes |
|---|---|---|
| Tow bar reference 1398 | ||
| Ball hitch T45M022 | 1 | |
| Bolts M12x65 - DIN931 | 2 | (*-*) |
| Bolts M12x60 - DIN931 | 2 | (*) |
| Security nuts M12 - DIN985 | 4 | (*-*) |
| Mounting tubes T45 | 2 | (*-*) |
| Mounting pieces T45 | 2 | (*-*) |
| Safety shackle (-s) (800000) | 1 | (*') |
| Bolts M8x30 - DIN933 | 2 | (A) |
| Security washers M8 - DIN128A | 2 | (A) |
| Socket plate holder P04 (-p) | 1 | (*') |
| Bolts M10x80 - DIN931 | 4 | (B-C-D) |
| Nuts M10 - DIN934 | 6 | (B-C-D-E) |
| Security washers M10 - DIN128A | 8 | (B-C-D-E-E') |
| Bolts M10x35 - DIN933 | 4 | (E-E') |
| Tubes ø16x2x55mm (10) | 3 | (C-D) |
| Tube ø16x2x57mm (9) | 1 | (B) |
| Counter plate left (7) | 1 | (B-C) |
| Counter plate right (8) | 1 | (C-D) |
| Side plate right (6) | 1 | (C-D) |
| Side plate left (5) | 1 | (B-C) |
All bolts and nuts: quality 8.8
Technical Notes and Specifications
Bumper Cut-out Description
A specific area on the underside of the rear bumper requires a cut. The diagram illustrates this as a hatched area, approximately 60mm wide and 20mm deep, located at the center of the bumper's lower rim.
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 |
Important Notes
- Consult your vehicle's dealer or owner's manual for the maximum permissible towing mass.
- Remove any bitumen coating or anti-rattle material from the fastening points before installation.
- Exercise caution during drilling to avoid damaging brake lines, electrical wiring, or fuel lines.
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