GDW Tow Bar for Opel Zafira (1999-....)
Brand: GDW
Model: Opel Zafira (1999 onwards), GDW Ref. 1163
EEC Approval: e4*94/20*1393*00
Product Overview
This document provides fitting instructions and technical details for the GDW tow bar system designed for the Opel Zafira, model years 1999 onwards.
The tow bar is identified by GDW reference number 1163 and has EEC approval number e4*94/20*1393*00.
The document includes a list of components, step-by-step installation guidance, and crucial technical specifications including torque values for fasteners.
The formula for towing capacity calculation is provided as: D = (max kg / max kg) x 0.00981 x (max kg / max kg) + s/ = 8.50 kN, with a maximum of 75 kg = 1300 kg.
Diagram Description
The diagrams illustrate the physical components of the tow bar system and their mounting points on the vehicle's chassis. Key mounting pieces are labeled as (-e) and (-d), with connection points designated by letters (A) and (B). Tubes are labeled (-f).
The diagrams also show the overall assembly of the tow bar structure and its attachment to the vehicle frame.
Fitting Instructions
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Step 1: Preparation
Remove the spare wheel, rear bumper, buffer beam, and exhaust system from the vehicle.
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Step 2: Chassis Preparation
On the rear side of the cross beam, drill four holes of 10.5mm diameter and enlarge them to 25mm. On the front side of the cross beam, remove the rubber caps located at the same height as the drilled holes.
Position the mounting pieces (-e) and (-d) with their holes (B) against these openings. Identify the correct position for point (A) on the provided drilling. Enlarge this specific drilling to 12mm diameter and insert the supplied cage nuts through the square opening in front of it. At point (A), insert the bolts and washers, but do not tighten them yet.
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Step 3: Tow Bar Mounting
Using the mounting pieces, insert the bolts at points (B). Insert the tubes (-f) into the chassis beam through the larger openings.
Align the tow bar, with its points (B), against the vehicle's bodywork onto the inserted bolts. Before fully tightening, place the supplied washers (28x14x1.5mm) between the tow bar and the bodywork. Insert all bolts and tighten them securely.
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Step 4: Re-assembly
Re-mount the exhaust system, buffer beam, and bumper. Replace the spare wheel.
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Step 5: Final Assembly
Assemble the ball (*) and tighten all fasteners securely.
Parts Composition
- 1 x Tow bar, reference 1163
- 1 x Ball hitch, T43M000
- 2 x Bolts M10 x 30mm (A)
- 4 x Bolts M12 x 40 (A)
- 4 x Bolts M12 x 110 + nuts (B)
- 2 x Cage nuts M10 (A)
- 4 x Washers 28x14x1.5mm (B)
- 4 x Tubes (-f) ø 24x4/69mm (B)
- 2 x Security washers 10mm (A)
- 8 x Security washers 12mm (B-*)
- 1 x Mounting piece (-e) (B)
- 1 x Mounting piece (-d) (B)
- 1 x Security shackle (*)
All bolts and nuts are quality 8.8.
Technical Specifications & Torque Values
Note: For the maximum permissible towing mass, consult your vehicle dealer or owner's manual.
Ensure any bitumen coating or sound-deadening material is removed from the fastening points.
Caution: When drilling, be careful not to damage any brake lines, electrical wiring, or fuel lines.
Bolt Torque Specifications (Quality 8.8)
| Bolt Size | Torque (Nm) | Torque (kgm) | Standard |
|---|---|---|---|
| M6 | 10.8 | 1.1 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M8 | 25.5 | 2.60 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M10 | 52.0 | 5.30 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M12 | 88.3 | 9.0 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M14 | 137.0 | 14.0 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M16 | 211.0 | 21.5 | DIN 912, DIN 931, DIN 933, DIN 7991 |
Bolt Torque Specifications (Quality 10.9)
| Bolt Size | Torque (Nm) | Torque (kgm) | Standard |
|---|---|---|---|
| M6 | 13.7 | 1.4 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M8 | 35.3 | 3.6 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M10 | 70.6 | 7.20 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M12 | 122.6 | 12.5 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M14 | 194.0 | 19.8 | DIN 912, DIN 931, DIN 933, DIN 7991 |
| M16 | 299.2 | 30.5 | DIN 912, DIN 931, DIN 933, DIN 7991 |
