Westfalia Tow Bar Installation and Operating Instructions
For Hyundai Tucson (2015-) and Kia Sportage (2016-)
Product Information
Part Number: 346103600001
Vehicles: Hyundai Tucson (2015 onwards), Kia Sportage (2016 onwards)
Technical Specifications:
- ECE Approval: E4 55R-01 0794
- Class: F
- D-Value: 11.26 kN
- Max. Vertical Load (S): 100 kg
- Max. Towing Capacity (R): 2200 kg
Manufacturers/Distributors: Monoflex Nordic AB, Monoflex ApS, WESTFALIA-Automotive GmbH, SIARR
General Safety and Installation Guidelines
Important Warnings:
- Always adhere to national guidelines for tow bar installation and approval.
- Any modification or alteration to the tow bar is strictly prohibited and will void the type approval.
- Ensure insulation material or underbody protection is removed from the tow bar mounting surfaces.
- This tow bar is designed solely for towing trailers and carrying loads. Any other use is forbidden.
- Parking Aid Interference: Vehicles equipped with parking assistance systems may experience malfunctions due to the tow bar components (ball, neck) being within the sensor's detection range. Adjust the sensor range or deactivate the parking aid if necessary. This is less likely with removable or pivoting ball hitches when the ball is not in the operating position.
- Safety: The tow bar is a safety-critical component. It must be installed by qualified technicians. Improper installation poses a serious risk of accidents.
- The Swedish text in this manual is considered binding.
- The tow bar complies with EU 1005/2010, Annex II, Point 1.2.1 and has withstood test forces equivalent to a towing vehicle's total weight of 2540kg.
- Specifications are subject to change without notice.
Parts List
The following components are included in the kit:
| Item No. | Quantity | Part Number | Description |
|---|---|---|---|
| 1 | 1 | FBA 1027 | Main Tow Bar Assembly |
| 2 | 1 | FFJ 12019H | Tow Bar Frame Component |
| 3 | 1 | FFJ 12019V | Tow Bar Frame Component |
| 4 | 4 | M12x40 (8.8) | Mounting Bolts |
| 5 | 8 | M10x1.25x35 (8.8) | Mounting Bolts |
| 6 | 4 | 13x24x2 | Washers |
| 7 | 8 | 10.5x22x2 | Washers |
| 8 | 8 | 10,2 | Nuts |
| 2 | M12.lock (8) | Locking Nuts | |
| 4 | M12x75 (8.8) | Mounting Bolts | |
| 4 | 13x24x2 | Washers | |
| 2 | 53.47 | Component | |
| 1 | FP17 | Component |
Installation Steps
Follow these steps carefully for correct installation:
- Step 01: Bumper Preparation (Hyundai Tucson & Kia Sportage)
Remove specific sections of the rear bumper or covers from both the Hyundai Tucson and Kia Sportage to allow access for the tow bar. - Step 02: Chassis Bracket Mounting (Hyundai Tucson: 2x, Kia Sportage: 3x)
Attach the designated mounting brackets to the vehicle's chassis. Note the different quantities required for each vehicle model: 2 brackets for the Hyundai Tucson and 3 brackets for the Kia Sportage. - Step 03: Bumper Modification (Hyundai Tucson)
For the Hyundai Tucson, a specific section of the rear bumper needs to be cut at a 45-degree angle to accommodate the tow bar hitch. This involves removing protective covers and potentially a small plastic piece. - Step 04: Chassis Bracket Attachment (Kia Sportage)
For the Kia Sportage, attach a specific bracket to the vehicle's chassis. - Step 05: Bumper Cutout (Kia Sportage)
For the Kia Sportage, a section of the rear bumper must be cut out. The diagram indicates dimensions of approximately 60mm and 55mm for the cutout area to allow the tow bar hitch to pass through. - Step 06: Main Tow Bar Assembly Mounting
Mount the main tow bar assembly to the prepared chassis points on both the Hyundai Tucson and Kia Sportage. - Step 07: Securing the Tow Bar Assembly
Secure the tow bar assembly using the provided hardware. Ensure bolts are tightened to the specified torque values: M12 bolts to 83 Nm, M10 bolts to 48 Nm, and M8 bolts to 24 Nm. - Step 08: Re-attaching Bumper Sections
Re-attach the bumper sections that were removed in Step 01. Ensure they are correctly positioned. - Step 09: Final Checks
Perform all final checks, ensure all components are securely fastened, and re-install any remaining covers or trim pieces.
Clearance Requirements
Ensure adequate clearance space around the tow ball and hitch mechanism as per the vehicle manufacturer's specifications and ECE-R 55 regulations. This includes:
- Clearance space must be guaranteed according to Appendix 7, Figures 25a and 25b of the ECE-R 55 regulations.
- Adherence to specific dimensions and angles is crucial for safe operation.
- The tow bar has been tested to withstand forces equivalent to a towing vehicle's total weight of 2540kg.
Declaration of Correct Installation
The installing company declares that the tow bar has been installed correctly according to the manufacturer's instructions and specifications, using the designated attachment points.
The user has been informed about the proper use and maintenance of the tow bar system.
