GDW Tow Bar Installation Guide for Alfa Romeo Stelvio (11/'16-)
Brand: GDW
General Advice and Information
This guide provides essential information for fitting a GDW tow bar to your Alfa Romeo Stelvio (model year 11/'16 onwards).
Fitting Recommendations
- Before starting, check the tow bar for any transport damage and ensure it is the correct reference for your vehicle.
- Read and follow all instructions in this mounting manual precisely.
- Present the tow bar under the vehicle before drilling or making any permanent attachments to verify placement.
- If drilling is required, ensure no wires (electrical, brake, etc.) are present. Remove any soundproofing or bitumen layers. Treat drilled holes and surrounding metal with an anti-corrosive product.
- If your vehicle has non-standard bumpers (e.g., special series, sport, tuning packages), consult GDW technical service before proceeding, as the tow bar may not fit.
- The tow bar supplied is assembled for storage; disassemble parts as needed for installation.
Guarantee Information
- To determine your vehicle's maximum towing weight, refer to the Certificate of Conformity (COC) or contact your dealer. Do not exceed the tow bar's technical specifications. See page 5 for formulas.
- The tow bar must be checked after the first 1,000 km of use and at least annually thereafter.
- Check all bolts and retighten if necessary.
- Repair any damage to the paint finish.
- Replace any components damaged due to an accident or collision.
- Grease the internal parts of detachable tow bar systems.
Usage Guidelines
- If the towing ball obstructs the license plate or fog light, it must be removed when not in use.
Towing Weight Specifications
Refer to your vehicle's Certificate of Conformity (COC) or contact your dealer to verify the maximum trailer weight. The D-value and S-value must not be exceeded.
D-value calculation: D = (max kg x max kg) / 0.00981 ≤ 11.40kN
S-value: ≤ 120kg (ball weight), ≤ 2300kg (trailer weight)
Parts List
The following parts are supplied with the tow bar kit (GDW REF. 2221):
- Part 1: Main tow bar assembly (GDW REF. 2221)
- Part 2: Left side bracket (GDW REF. 2)
- Part 3: Right side bracket (GDW REF. 3)
- Part 4: Washers (4x DIN125-A12-140HV-ELVZ)
- Part 5: Washers (4x DIN9021-M12-ELVZ)
- Part 6: Spring washers (8x DIN128A-M12)
- Part 7: Bolts (8x DIN933-M12x40)
- Part 8: Nuts (4x DIN934-M12)
- Part 9: Washers (6x DIN9021-M8-ELVZ)
- Part 10: Spring washers (6x DIN128A-M8)
- Part 11: Nuts (6x DIN934-M8)
- Part A: Tow ball mount (900.053)
- Part B: Tow ball (GDW REF. 900.025)
- Part C: Tow ball retaining nut (GDW REF. 900.026)
- Part D: Tow ball locking pin/clip (GDW REF. 900.011, Ø 21.3 X 11.7)
- Part E: Bolts (2x DIN931-M12 x 70)
- Part F: Nuts (2x DIN985-M12)
- Part G: Electrical socket housing (GDW REF. PO4)
- Other hardware includes: 944.M006
Tools required include: TX20, TX30, 4, 13, 19 (wrenches/sockets).
Installation Steps
Follow these steps carefully for proper installation:
Step 1: Accessing the Rear Area
Open the vehicle's tailgate. Remove interior trim panels from the rear bumper area to gain access to mounting points.
Step 2: Bumper Removal
Carefully remove the rear bumper. This may involve releasing clips or fasteners. Refer to vehicle-specific guides if unsure.
Step 3: Tail Light Removal
Remove the rear tail lights to allow access to mounting bolts.
Step 4: Wheel Arch Liner Removal
Remove the plastic liner from the wheel arch on both sides to access chassis mounting points.
Step 5: Undertray/Splash Guard Removal
Remove any undertray or splash guard components that may obstruct the tow bar installation.
Step 6: Installing Main Bracket
Position the main tow bar bracket (Part 1) against the vehicle's chassis mounting points. Secure it using the provided bolts (Part 7), washers (Parts 4, 5), and nuts (Part 8). Do not fully tighten yet.
Step 7: Attaching Side Brackets
Attach the side brackets (Parts 2 and 3) to the main bracket (Part 1) using appropriate hardware. Ensure correct orientation.
Step 8: Securing Brackets to Chassis
Align the side brackets with the chassis mounting points and secure them using bolts (Part E), washers (Parts 9, 10), and nuts (Part 11). Tighten all bolts progressively.
Step 9: Torqueing Fasteners
Torque all fasteners to the specified values. For M12 bolts (Parts 7, E), torque to 93.0 Nm. For M8 bolts (Parts 7, 11), torque to 27.3 Nm.
Step 10: Installing Tow Ball Assembly
Assemble the tow ball mount (Part A), tow ball (Part B), and retaining nut (Part C). Insert the locking pin (Part D) to secure the ball. Attach this assembly to the main tow bar bracket.
Step 11: Electrical Socket Housing
Mount the electrical socket housing (Part G) to the designated bracket on the tow bar assembly.
Step 12: Bumper Modification (if necessary)
If required, mark and cut the rear bumper according to the dimensions provided (approx. 85mm width, 70mm height, 60mm depth) to accommodate the tow bar.
Step 13: Re-installing Components
Re-install the rear bumper, tail lights, and any removed trim panels. Ensure all connections are secure.
Step 14: Final Check
Perform a final check of all connections and ensure the tow bar is securely fitted.
Clearance and Regulatory Information
Ensure that the clearances specified in Appendix VII, diagram 25 (a,b) of regulation nr. 55 are maintained. This includes specific angular and linear clearances for safe operation.
The vehicle's maximum laden weight must be considered when towing.
