GDW Tow Bar Installation for Alfa Romeo 166 (1999-....)
GDW Reference: 1166
General Information & EEC Approval
This document provides fitting instructions for a GDW tow bar for the Alfa Romeo 166, model years 1999 onwards.
EEC Approval Number: e6*94/20*0468*00
Towing Capacities:
- D = (max kg x max kg) / (max kg + max kg) x 0.00981 ≤ 9.80 kN
- Maximum vertical load (s/): 75 kg
- Maximum towing mass: 1800 kg
Manufacturer: GDW nv
Address: Hoogmolenwegel 23, B-8790 Waregem
Contact: TEL. +32(0)56 60 42 12(5) | FAX. +32(0)56 60 01 93 | Email: gdw@gdwtowbars.com | Website: www.gdwtowbars.com
Installation Instructions
- Disassemble the bumper and rear protection plate. Remove the spare wheel and interior trim from the trunk.
- Place mounting piece (-h) in the spare wheel well, aligning points (D) with the vehicle's pre-drilled holes (pierce the bitumen coating). Align points (B) with the rear body panel drillings (remove adhesive tape). Insert bolts and place mounting plate (-k) under the spare wheel well, aligning points (D) on these bolts, but do not tighten yet.
- Mount pieces (-i) and (-n) on the underside of the chassis beams at the pre-drilled holes (remove tape or caps). Insert tubes through the large chassis holes (C and C') and place mounting pieces (-j) and (-g) onto these tubes. Piece (-j) has angled drillings and fits on the left. Insert bolts, but do not tighten yet.
- Place the tow bar tube with points (G) and (G') onto points (G) and (G') of pieces (-i) and (-n). Points (B) align with the rear body panel drillings. Points (E) align with piece (-k). Insert all bolts.
- Mount piece (-l) with points (F) onto piece (-k). Points (A) align with the threaded holes in the rear cross-beam. Insert the necessary bolts.
- Mount (*) onto points (E) and (F) of mounting piece (-k), insert bolts, and tighten all firmly. Secure the socket holder with (*).
- Before refitting the bumper, make an incision on the underside as indicated in the enclosed drawing.
Parts List (Composition)
| Part | Quantity | Reference/Notes |
|---|---|---|
| Tow bar ball T43M000 | 1 | (*) |
| Bolt M10x30/1.25 | 2 | (A) |
| Bolt M10x30 + nuts | 4 | (B-G') |
| Bolt M10x30 | 2 | (G) |
| Bolt M10x35 + nuts | 4 | (D) |
| Bolt M10x90 + nuts | 2 | (C') |
| Bolt M10x100 (DIN7991) + nuts | 2 | (C) |
| Bolt M12x45 | 2 | (E) |
| Bolt M12x45 + nuts | 2 | (F) |
| Tube ø25x14/59 | 4 | (C-C') |
| M10 washer | 16 | (A-B-C-C'-D-G-G') |
| Washer 40x12x2 | 2 | (A) |
| Washer 40x12x4 | 4 | (D) |
| M12 security washer | 4 | (E-F) |
| Mounting piece (-i) | 1 | (G-G') |
| Mounting piece (-j) | 1 | (C) |
| Mounting piece (-g) | 1 | (C') |
| Mounting piece (-h) | 1 | (B-D) |
| Mounting piece (-l) | 1 | (F) |
| Mounting piece (-k) | 1 | (D-E) |
| Mounting piece (-o) | 1 | (G-G') |
| Safety shackle (-s) | 1 | (E-F) |
| Socket holder (P03) | 1 | (E) |
Note: Please consult your car dealer or owner's manual for the maximum permissible towing mass. Remove any bitumen coating on the fastening position for the tow bar. When drilling, be careful not to damage any brake lines, electrical wiring or fuel lines.
Technical Specifications & Torque Values
All bolts and nuts: Quality 8.8
Torque Values (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 |
All bolts and nuts: Quality 10.9
Torque Values (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 |
Bumper and Panel Cutout Information
The following describes the necessary cuts to the vehicle's bumper and rear panel for tow bar installation.
Bumper Cutout
The hatched area of the bumper needs to be cut away. Key points are:
- B: The bumper
- O: The lower rim of the bumper
- M: The middle of the bumper
Approximate dimensions for the cutout are 130mm (width) and 145mm (height) at the lower center.
Rear Panel Cutout
The hatched area of the rear panel needs to be cut away. Key points are:
- B: The bumper
- O: The lower rim of the bumper
- M: The middle of the bumper
Approximate dimensions for the cutout are 235mm (width) and 195mm (height) at the lower center.
