Westfalia Automotive Tow Bar Installation Guide

Introduction

This document provides detailed instructions for the installation and operation of a Westfalia Automotive tow bar system designed for the Kia Sportage V (NQ5e) model, manufactured from November 2021 onwards.

Languages Supported: This manual is available in multiple languages, including German (DE), Czech (CS), Danish (DA), Spanish (ES), French (FR), Finnish (FI), English (EN), Greek (EL), Hungarian (HU), Italian (IT), Norwegian (NO), Dutch (NL), Polish (PL), Russian (RU), and Swedish (SV).

Safety and General Information

Important Safety Precautions:

• National guidelines concerning the approval and installation of tow bars must be strictly observed.
• Any alterations or modifications to the tow bar system are prohibited and will void the operating license and warranty.
• Ensure insulating compound or underbody coating is removed from the vehicle's contact surfaces where the tow bar is mounted.
• The tow bar is designed exclusively for towing trailers and for use with load carriers. Any other use is strictly forbidden.
• Vehicles equipped with parking assistance systems (e.g., parking sensors) may experience malfunctions after tow bar installation if components (like the tow ball) interfere with the sensors. Adjust the sensing range or disable the system if necessary. Systems with removable or pivoting tow balls may avoid this issue when the ball is removed.
• The tow bar is a critical safety component and must only be installed by qualified, authorized professionals. Improper installation can lead to serious accident hazards.
• The German text of this manual is considered the binding and authoritative version.
• Modifications and changes are reserved by the manufacturer.

Technical Specifications

Approval Number: E11 55R01/07 12109

Coupling Class: A 50-X

D-Value: 10.8 kN (max)

Vertical Load (Nose Weight) S: 132 kg (max)

Vehicle Weight: 19.7 kg (for the tow bar itself)

Clearance Requirements (ECE-R 55 Annex 7): Specific clearance dimensions must be maintained around the tow ball and vehicle interface, as detailed in the regulations.

Torque Specifications:

Note: Torque values are critical for safety. Always use a calibrated torque wrench.

Parts Included

The tow bar kit typically includes the following hardware:

• 6 x M12 x 40mm bolts (Grade 8.8)
• 2 x M6 x 16mm bolts (Grade 8.8)
• 4 x M12 x 30mm bolts
• 2 x M12 x 1.75 bolts
• 2 x M6 x 1.00 bolts
• Neck Guide component
• Various other mounting brackets and hardware specific to the vehicle model.

Refer to the diagrams for specific part identification and placement.

Tools Required

The following tools are typically needed for installation:

• Socket wrenches and extensions (e.g., 10-24 mm range)
• Torque wrench (0-220 Nm range)
• Standard wrenches
• Screwdrivers
• Measuring tape
• Safety glasses
• Work gloves

Installation Steps

Follow these steps carefully for proper installation. Ensure all safety precautions are observed.

Step 1: Vehicle Preparation

Access the rear of the Kia Sportage V. Identify the designated mounting points on the vehicle's chassis, typically located near the rear bumper and frame rails. Remove any protective covers or bumper sections as indicated by the vehicle manufacturer's guidelines or the tow bar kit's specific requirements.

Step 2: Mounting the Tow Bar Frame

Position the main tow bar frame assembly against the vehicle's chassis, aligning the frame's mounting holes with the chassis's mounting points. Insert the specified bolts (e.g., M12 x 40mm, M6 x 16mm) through the frame and into the chassis. Do not fully tighten the bolts at this stage; leave them slightly loose to allow for adjustment.

Step 3: Attaching Side Brackets

Connect any required side support brackets to the main tow bar frame and the vehicle's chassis. Ensure these brackets are correctly oriented and aligned with their respective mounting points.

Step 4: Initial Tightening

Snug-tighten all bolts and nuts installed in the previous steps. This will hold the assembly in place while allowing for minor adjustments.

Step 5: Final Torqueing

Using a calibrated torque wrench, tighten all M12 bolts to their specified torque values. For the main frame and side brackets, this is typically 83 Nm for M12 bolts (Grade 8.8). Refer to the torque table for specific bolt sizes and grades.

Step 6: Installing the Detachable Tow Ball

Insert the detachable tow ball neck into the tow bar receiver. Ensure it is fully seated. Operate the locking mechanism by inserting the key and turning it clockwise until it clicks and locks the ball in place. A green indicator should confirm correct locking. Verify that the tow ball is securely fitted and has minimal play.

Note: Always check the locking mechanism and ensure the green indicator is visible before using the tow bar.

Step 7: Electrical Connection

Route the tow bar's electrical wiring harness. Connect it to the vehicle's trailer socket or wiring loom according to the vehicle's electrical system and the tow bar manufacturer's instructions. Secure the harness to prevent damage or interference with moving parts.

Step 8: Reassembly

Refit any bumper sections, trim panels, or underbody covers that were removed during installation. Ensure all fasteners are reinstalled correctly and that the vehicle's appearance is restored.

Step 9: Final Checks and Operation

Operation of the Detachable Tow Ball:

• To Attach: Insert the tow ball into the receiver. Push it upwards until it clicks into place. Turn the locking key clockwise to secure the ball. A green indicator should be visible, and the lock should engage. Ensure the ball is firmly seated and locked.
• To Detach: Insert the key into the lock cylinder and turn it counter-clockwise. Push the release lever downwards. While holding the lever down, pull the tow ball downwards to remove it.
• Important Checks: Always verify that the tow ball is securely locked before use by checking the green indicator and ensuring there is no excessive play (e.g., a gap greater than 5mm between the ball and receiver housing when locked).

Maintenance: Periodically clean the tow ball and locking mechanism. Avoid using high-pressure washers directly on the mechanism. Store the detachable tow ball in a safe place when not in use.

Weight Limits: Always adhere to the specified D-Value (10.8 kN) and Vertical Load (Nose Weight) (132 kg) limits. Do not exceed the vehicle's towing capacity.

Parking Sensor Compatibility: Be aware that parking sensors may be affected. If malfunctions occur, adjust the sensor range or disable the parking assist system.

Declaration of Correct Installation

This section typically contains a declaration by the installer confirming that the tow bar has been fitted correctly according to regulations and manufacturer instructions, and that the vehicle owner has been informed about the proper use and maintenance of the tow bar system.

Clearance and Regulatory Compliance

Installation must comply with ECE-R 55 regulations, including specific clearance requirements as detailed in Annex 7, Figures 25a and 25b. These ensure proper function and safety, especially concerning vehicle dynamics and trailer interaction.