GDW Tow Bar for Opel Insignia Break (2009-)
GDW Reference: 1762
Manufacturer: GDW nv
Vehicle: Opel Insignia Break, 01/2009 - onwards
Product Overview & Approval
This document provides details for the GDW tow bar system designed for the Opel Insignia Break, model year 2009 onwards.
EEC Approval Number: e6*94/20*0797*00
Towing Specifications:
- D = Max. towing weight (kg)
- S = Max. towing weight (kg)
- D = [Formula description: Max. towing weight (kg) X 0.00981] ≤ 10.5 KN
- S/Max. = 85 Kg
- Max. = 2100 Kg
Manufacturer Contact: GDW nv, Hoogmolenwegel 23, B-8790 Waregem, Belgium. TEL: +32 (0)56 60 42 12, FAX: +32 (0)56 60 01 93, E-Mail: gdw@gdwtowbars.com, Website: www.gdwtowbars.com
Parts List and Specifications
Diagram Description (Fig. 2): Illustrates the tow bar assembly (T45J006) and optional parts (AFN-J006), along with delivered components.
Delivered Parts:
- 4 x Din 931 M12x70 bolts
- 4 x Din 985 M12 nuts
- 2 x GDW ref 800008 mounting pieces
- 2 x GDW ref 800011 mounting pieces
Component Composition (Samenstelling / Composition / Zusammenstellung):
| Quantity | Description | GDW Ref. |
|---|---|---|
| 8 x | DIN 933-M12x35 -8.8 bolts | 800.053 |
| 8 x | DIN 128-A12-FSt washers | P04 |
| 4 x | DIN 128-A10-FSt washers | |
| 4 x | DIN 934-M10 -8.8 nuts | |
| 4 x | DIN 934-M12 -8.8 nuts | |
| 4 x | DIN125A M10 washers (Ø10.5x20x2) | |
| 4 x | Round washer 40x35x12x4 | 905003 |
| 1 x | Tow bar assembly (T45J006) | 1762 |
Bolt Torque Specifications:
| Bolt Type | Torque (Nm) | Torque (kgm) |
|---|---|---|
| Quality 8.8 | ||
| 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 |
| Quality 10.9 | ||
| 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 |
| Quality 12.9 | ||
| M6 | 18 | 1.8 |
| M8 | 43 | 4.4 |
| M10 | 87 | 8.9 |
| M12 | 150 | 15.3 |
| M14 | 240 | 24.5 |
| M16 | 370 | 37.7 |
Installation Instructions
Bumper Cut-out (Fig. 1): The hatched area of the bumper must be cut away. 'B' refers to the bumper, 'O' to the lower rim, and 'M' to the middle of the bumper.
General Fitting Steps:
- Disassemble the bumper: Remove the exhaust pipe and the aluminium buffer beam.
- Position the tow bar with points (A) onto the existing bolts where the buffer beam was attached. Insert bolts and washers, and hand-tighten.
- Insert mounting pieces (ref. 1 left, ref. 2 right) into the chassis beam via rear openings. Align points (B) with the chassis beam drillings and points (C) with the tow bar drillings. Secure with bolts and washers, tightening them firmly (refer to torque specifications).
- Make an incision in the lower part of the bumper as indicated in Fig. 1. Mount the bumper back onto the vehicle.
- Assemble the ball hitch, socket holder, and safety eye. Insert bolts and tighten securely (refer to torque specifications).
Bumper Disassembly Details:
- Remove 2x2 screws from attachment blocks near the rear door.
- Remove 3 plastic nails from the underside of the bumper.
- Remove 2x3 screws from the mudguard.
- Unclip the sides of the bumper.
- Unclip the middle section of the bumper.
- Slide the bumper backwards.
Clearance Specifications (Fig. 12): The clearance must comply with supplement VII, diagram 30 of guideline 94/20/EG. Ensure correct clearance for total laden weight of the vehicle.
Important Recommendations
To be kept in the vehicle:
Fitting:
- Before fitting, check the tow bar for transport damage and verify the correct reference for the vehicle.
- Read and follow the fitting instructions precisely.
- Present the tow bar under the vehicle before starting installation to check alignment.
- When drilling, ensure no existing wiring (brake, electrical, fuel lines) is damaged. Remove soundproofing material, clean drilled holes, and protect them with an anti-corrosive product.
- If the vehicle has non-standard bumpers (special series, sport, tuning parts), contact GDW technical service before proceeding.
- The tow bar is delivered assembled for storage; parts must be disassembled for fitting.
Guarantee:
- Do not exceed the indicated maximum towing weight, 'D', and 'S' values.
- The tow bar must be checked after the first 1,000 km of use and at least annually.
- Check and retighten all bolt connections as necessary.
- Repair any paint damage.
- Replace any components damaged by an accident or collision.
- Grease the internal parts of detachable tow bar systems.
Usage:
- If the tow ball covers the license plate or fog light, it must be removed when not in use.
