Towbar Fitting Instruction

Components

Bolt Pack

Fitting Procedure

1. Remove the undertray. Remove the heat shield from the right hand chassis rail. Remove and discard the towing eye from the left hand chassis rail.
2. Locate the threaded nuts in the underside of each chassis rail and loosely attach side arms (C) & (D) using 1.25 fine pitch bolts (G) with shakeproof and heavy duty washers (J) under the bolt heads.
3. Insert towbar (A) between side arms (C) & (D) and loosely attach using bolts (H).
4. Attach swan neck (B) & electrical mounting bracket (EP) to towbar (A) using bolts (F) with 1 spacer (B1) at each side of the swan neck. The electrical mounting bracket carries type approval information required by law and must always be fitted as shown.
5. Tighten all bolts ensuring assembly remains square and level. Replace heat shield using longer bolt (I) with flat washer (K) under the bolt head. If additional exhaust clearance is required, drill clearance holes in the heat shield for bolt heads (G).
6. Cut section from undertray as illustrated and refit.

Fitting Diagram Description

The fitting diagram illustrates the towbar installation for a Toyota Avensis Estate. It shows the main towbar assembly (A) mounted to the vehicle's chassis via left and right side arms (C and D, respectively). The detachable swan neck (B) and the electrical mounting bracket (EP) are shown attached to the towbar. Various bolts (F, G, H) and heavy-duty washers (J) are depicted securing these components to the chassis and towbar. A separate detail shows an 'UNDERTRAY CUT DETAIL (OUTSIDE FACE SHOWN)' with specific dimensions indicated: 285mm, 80mm, 330mm, 35mm, and 35mm, guiding necessary modifications to the vehicle's undertray for clearance.

Bolt Tightening and Towing Limits

Torque Settings:

• ISO Coarse Pitch: M8 = 29Nm, M10 = 58Nm, M12 = 102Nm, M16 = 252Nm
• ISO Fine Pitch: M8 = 31Nm, M10 = 61Nm, M12 = 111Nm

Important Note: The vehicle manufacturer's specification for the trailer weight and nose load limits must be observed.

Important Product Information & Guarantee

(To be retained with the vehicle and passed to subsequent owners)

Thank you for purchasing a PCT Automotive product. Please read the following information carefully before fitting or using your PCT Automotive product.

Guarantee

PCT Automotive offers a free repair or replacement for defective goods. For towbars manufactured by PCT Automotive, this applies during the economic lifetime of the vehicle. For all other PCT Automotive products, the guarantee is valid for 3 years from the date of order. This guarantee is conditional upon defects arising from faulty design, workmanship, or materials, and not from failure to follow instructions, modification, misuse, neglect, interference with installation, damage, abuse, or failure to carry out reasonable inspection, maintenance, or adjustment. The guarantee is subject to PCT Automotive's standard terms and conditions of sale, available upon request.

Towing Limits

PCT Automotive towbars are designed to comply with the vehicle manufacturer's maximum recommended trailer weight and nose load limits. Towing with gross weights exceeding these recommendations at any time will invalidate the guarantee and cancel any liability for damage. Towing a twin axle trailer, towing over rough ground, or using a bicycle/motorcycle carrier exerts extreme loads on the towbar, requiring extra care to ensure vehicle manufacturer's maximum recommended limits are not exceeded.

Product Identification Mark

Your product is supplied with a product identification mark. This mark contains essential product and batch code information. If the product is type approved, it also includes legally required type approval details. This mark must not be defaced, removed, or damaged under any circumstances.

Installation, Inspection, Maintenance and Adjustment

General Installation

• Products should only be fitted by competent persons.
• Read the product fitting instructions carefully and verify all components are included before commencing installation.
• Inspect the vehicle for corrosion and/or accident damage. Towbars must not be fitted to vehicles that are not roadworthy or that have corrosion or accident damage.
• Clean all areas where parts are to be fitted, removing road dirt, underseal, and sound deadening mastic to ensure correct component seating.
• Bumper cut information is provided as a guide only. Variations in vehicle models may occur, so the fitter must always check the necessity and correct size/shape of the bumper cut before proceeding.
• Remove all drilling swarf from the vehicle and treat all drilled holes with an appropriate rust inhibitor.
• Do not fully tighten bolts before the towbar is completely fitted, unless specifically instructed. This allows for minor adjustments to be made before final tightening.

Paint & Corrosion

Towbars manufactured by PCT Automotive undergo a phosphate chemical pre-treatment followed by an epoxy/polyester powder coat finish. For long-lasting appearance and to prevent corrosion, the towbar should be regularly inspected for paint damage and repainted with appropriate finishing paint or underseal as necessary. The vehicle should also be regularly checked for any corrosion that could affect the towbar installation. Towbars must not be used on vehicles suffering from corrosion that could compromise the towbar installation.

Bolts

All towbar fixing bolts must be checked initially after the first 300 towing miles. Subsequent checks should be performed every 3,000 towing miles or in conjunction with the vehicle manufacturer's recommended service intervals, whichever comes first. Bolts should be tightened using an appropriate torque wrench to the settings specified in the towbar fitting instruction.

Electrical Installation, Test/Commissioning and Maintenance

Failure to comply with the following electrical installation instructions may cause damage to the towing vehicle's wiring loom and/or towing electrics installation.

• When using displacement tap connectors (e.g., Scotchloks), always use the correct colour-coded connector for the cable size. For PCT Automotive manufactured relays with integral cables, use red tap connectors for cables between 0.5mm² and 1mm² conductor cross-sectional area.
• After installing the 12N/12S sockets, apply a water displacement agent (e.g., WD40) into the rear connection void via the water drain hole and into the front pins under the socket flap before testing. This socket maintenance should be performed at least twice a year, in spring and autumn.
• The towing electrics test procedure must be conducted with the engine running. If towing relays fail to function correctly (with the engine running and no other vehicle electrical systems active), check the vehicle's battery voltage, which should be between 13V and 14V. If the voltage is incorrect, check the battery/alternator condition.
• Always ensure that the trailer/caravan/lighting board's own electrical systems are installed and functioning correctly before coupling to the vehicle's 12N/12S sockets.
• Every six months (recommended in spring and autumn), check the vehicle's battery and alternator to ensure correct electrical functioning. Verify the mechanical soundness and electrical quality of all electrical installation connections, including the earth connection. Check plugs, sockets, relays, and fixings for water ingress, mechanical soundness, electrical quality, and general wear and tear.

Guarantee Validation and Reference

Please complete the following information to validate the guarantee and for future reference:

Vehicle Owner Name & Address: [Field for input]

Vehicle Make & Model: [Field for input]

Vehicle Registration Number: [Field for input]

Fitter Name & Address: [Field for input]

Date Towbar Fitted: [Field for input]

For any comments or suggestions regarding PCT Automotive products, please contact PCT Automotive, Holbrook Industrial Estate, Sheffield S20 3GH or email techsupport@pctautomotive.com. Your feedback helps PCT Automotive continually upgrade its products to meet high standards.

© PCT Limited (Rev. Jan 2006)