WESTFALIA Tow Bar Installation Guide for Toyota Corolla Verso

General Information and Safety Warnings

This document provides installation instructions for the WESTFALIA tow bar system for the Toyota Corolla Verso.

Important Safety Information:

• National directives regarding installation approvals must be observed.
• Any modifications or alterations to the tow bar system are strictly prohibited and will void the operating license.
• Remove any insulating compound or underbody protection from the vehicle's contact surfaces where the tow bar is to be mounted.
• The tow bar is designed for towing trailers and carrying loads. Any other use is prohibited.
• Parking Aid Interference: Vehicles equipped with parking assistance systems may experience malfunctions if tow bar components are within the sensor's detection range. Adjust the sensor range or deactivate the parking aid if necessary. For removable or pivoting ball tow bars, malfunctions are unlikely if the ball is not in the operating position.
• The tow bar is a safety-critical component and must only be installed by qualified professionals. Incorrect installation can lead to serious accidents. ⚠️
• The German text of this manual is binding.
• Subject to change without notice.

Technical Specifications

Tow Bar Type: 335 322

Vehicle: Toyota Corolla Verso

Functional Type: R1

Hitch Class and Type: A50-X

Homologation: e13*94/20*00*1799

D-Value: 8.6 kN

Max. Vertical Load (S): 75 kg

Towing Mass: Refer to the vehicle's registration document.

The D-Value is calculated based on the towing vehicle's maximum gross mass (T) and maximum towing mass (C) according to Directive 94/20/EC.

Parts List

Refer to installation diagrams for specific part numbers (1-9) and their placement.

Installation Instructions

Follow these steps carefully for proper installation. Ensure all fasteners are tightened to the specified torque values.

Step 1: Vehicle Preparation

Identify the Toyota Corolla Verso rear end. Ensure you have the necessary tools and parts.

Step 2: Locate Mounting Points

On the rear of the vehicle, locate the designated mounting points (labeled 'a' and 'b' in diagrams) on the chassis. Prepare to insert fasteners (labeled 'c').

Step 3: Chassis Access

Access the relevant chassis areas. Insert fasteners ('c') into the designated holes.

Step 4: Bumper and Undertray Removal

Remove any bumper sections or undertrays that obstruct access to the mounting points. Note specific parts (d, e, f) and fasteners to be removed or retained.

Step 5: Mount Initial Bracket

Attach the first main bracket (part 1) to the vehicle chassis using the provided bolts.

Step 6: Mount Side Brackets

Secure the side brackets (parts 4 and 5) to the chassis using M10x35 bolts and 10.5x20x2 washers.

Step 7: Attach Tow Bar to Chassis

Connect the tow bar structure (parts 8/9) to the vehicle chassis using M8x25 bolts and 8.5x24x2 washers.

Step 8: Connect Tow Bar to Brackets

Attach the tow bar (part 8) to the previously mounted brackets (1, 4, 6) using M8x25 bolts, 8.5x24x2 washers, M10x35 bolts, and 10.5x20x2 washers.

Step 9: Connect Second Tow Bar Section

Attach the other section of the tow bar (part 9) to brackets (1, 5, 7) using M8x25 bolts, 8.5x24x2 washers, M10x35 bolts, and 10.5x20x2 washers.

Step 10: Final Fastening of Tow Bar Assembly

Secure the entire tow bar assembly to the chassis (part 1) and its supporting brackets (6/7, 4/5). Tighten bolts to the following torque specifications:

• M8x25: 30 Nm
• M10x35: 40 Nm
• M10x55: 40 Nm

Step 11: Install Tow Ball Receiver

Mount the tow ball receiver (part 1) onto the tow bar structure (parts 4 and 5). Use M10x35 bolts and 10.5x20x2 washers. Tighten to 40 Nm.

Step 12: Install Protective Cover

Install any protective covers or brackets using 6.4x24x2 bolts and M6x20 nuts. Tighten to 8 Nm.

Step 13: Electrical Socket Mounting

Mount the electrical socket housing (labeled 'a' and 'b') to the tow bar structure.

Step 14: Bumper Modification

If required, carefully cut the vehicle's rear bumper according to the specified dimensions: R5 radius, 80mm, and 202mm.

Step 15: Final Vehicle Check

The tow bar is now installed on the vehicle.

Step 16: Install Tow Ball

Insert the tow ball (part 2) into the receiver (part 1). Secure it using M12x75 bolts and 13x24x2.5 washers. Tighten to 95 Nm.

Clearance Requirements (Directive 94/20/EC)

Ensure the following clearances are met as per Directive 94/20/EC, Annex VII, Diagram 30 and 33:

Diagram 30 Clearances:

• Minimum clearance around the tow ball: min. 32mm, min. 55mm, min. 140mm, min. 65mm, min. 45mm, min. 75mm.
• Maximum angles: max. 45°, max. 30°, max. R 14.5, max. R 40.
• Dimensions: 350-420mm (refer to vehicle's gross weight).

Diagram 33 Clearances (Hand Lever):

• Minimum clearance for hand lever: ≥60mm, ≥100mm.

Declaration of Correct Installation

This section is for the installer to complete, declaring that the tow bar has been installed correctly according to specifications and that the vehicle owner has been informed about its use and maintenance.