Westfalia Tow Bar Installation Guide

Product Overview

This document provides comprehensive installation instructions for the Westfalia tow bar, part number 306 276 600 001, designed for Fiat Sedici and Suzuki SX4 vehicles. It includes detailed steps, hardware lists, technical specifications, safety warnings, and compliance information.

Technical Specifications

Hardware Included

• 2x M12x75 (10.9) bolts
• 2x M10x125 (8.8) bolts
• 2x M10x115 (8.8) bolts
• 2x M10x105 (8.8) bolts
• 4x M10x30 (8.8) bolts
• 8x M10x25 (8.8) bolts
• 3x 13x24x2.5 washers
• 18x 10.5x25x3 washers
• 4x 13x26x30 washers
• 2x M12 (10) nuts
• 18x M10 (8) nuts

Installation Instructions

Step 1: Preparation

Disassemble the rear bumper by first loosening the covers in the wheel arches. Fold the rear seat and boot cover forward. Disassemble the rear and side paneling. Ensure the boot floor is clear and accessible. Unfasten the exhaust silencer.

Step 2: Mark and Drill Boot Floor

Locate markings (crosses) at point "a" on the left and right of the boot floor (refer to Diagram I). Centrically drill ø10.5 mm holes in the boot floor at these markings and deburr them. Place plates 3 on the left and right sides of the boot and fix them at point "a" with M10x25 bolts. Align plates 3 and transfer/mark bore holes "b", "c", "d", and "e" onto the vehicle body. Remove plates 3. Drill and deburr the transferred holes: "b", "c", and "d" to ø22 mm, and "e" to ø10.5 mm.

Diagram I shows the location of markings 'a' on the boot floor.

Step 3: Mark and Drill Chassis Beams

Centrically mark/punch bore holes "b" and "c" from underneath on the longitudinal beams according to Diagram II. Drill and deburr holes "b" and "c" to ø12 mm from underneath the longitudinal beams.

Diagram II illustrates the positioning of holes 'b' and 'c' on the chassis beams and the placement of spacer tubes.

Step 4: Install Spacer Tubes and Plates

From the boot side, insert spacer tubes 6 at "b", spacer tubes 7 at "c", and spacer tubes 8 at "d" into the longitudinal beams. Ensure correct positioning of spacer tubes 6 and 7 (refer to Diagram II). Insert plates 3 and slide M10x125 bolts at "b", M10x115 bolts at "c", and M10x105 bolts at "d" through plates 3 and the already inserted spacer tubes. Loosely screw plates 3 at "a" and "e" to the boot floor using M10x25 bolts, 10.5x25x3 washers, and M10 nuts.

Step 5: Attach Base Part and Holders

Position base part 1 under the vehicle and loosely screw it at "b" and "c" using 13x26x30 wedge washers, 10.5x25x3 washers, and M10 nuts. Ensure correct positioning of wedge washers (refer to Diagram II). Loosely screw holders 4 and 5 at "d" using the already inserted bolts, 10.5x25x3 washers, and M10 nuts. Now, loosely screw holders 4 and 5 to base part 1 at "e" using M10x30 bolts, 10.5x25x3 washers, and M10 nuts.

Step 6: Align and Tighten

Align the tow bar assembly and tighten all bolts and nuts. Tightening torque for M10 at points "a", "b", "c", "d", "e", and "f" is 40 Nm.

Step 7: Modify Bumper and Reassemble

Cut out the boot side paneling according to Diagram III. Using the supplied template, cut out the hatched area from the underside of the bumper. Place the template on the outside of the bumper and fix it. The line "Y0" corresponds to the vehicle's center line. Reassemble all disassembled vehicle parts.

Diagram III shows the area to be cut from the bumper, with dimensions and reference line Y0.

Step 8: Install Ball Hitch and Socket Holder

Slide ball hitch 2 between the plates at "g" and screw it in using M12x75 bolts, 12.5x24x2.5 washers, and M12 nuts. Simultaneously attach the socket holder 9. Tightening torque for M12 at point "g" is 95 Nm.

Important Notes & Warnings

• Note: National guidelines regarding installation approvals must be observed.
• Warning: Any alterations or modifications to the tow bar are prohibited and will void the operating license.
• Remove insulating compound or underbody coating from the vehicle in the area of the tow bar's contact surfaces.
• The tow bar is intended for towing trailers and for load carriers. Any other use is prohibited.
• Vehicles with parking assist systems may experience malfunctions after tow bar installation if parts (ball bar, coupling ball) are within the sensor range. Adjust the sensing range or disable the parking assist system if necessary. For removable or pivoting ball bars, malfunctions are unlikely if the ball bar is removed from its operating position.
• The tow bar is a safety-critical component and must only be installed by qualified companies. Improper installation poses a serious accident hazard! The German text of this manual is binding.
• Subject to change.

Declaration of Correct Installation

The undersigned company declares that the tow bar type [...] has been installed correctly, respecting the attachment points and specifications provided by the manufacturer on the vehicle [...].

It is also declared that the vehicle user has been informed about the USE and MAINTENANCE of the device.

Available Languages

This manual is available in the following languages:

• German (D)
• Czech (CZ)
• Danish (DK)
• Spanish (E)
• French (F)
• Finnish (FIN)
• English (GB)
• Greek (GR)
• Italian (I)
• Norwegian (N)
• Dutch (NL)
• Polish (PL)
• Swedish (S)