Towbar, flange (2001, 2002)

• Turn the ignition key to position 0. Remove the ignition key from the ignition switch.

• Fold up and remove the floor hatch (1).
• Fold up and remove the storage cover (2).
• Remove the side panel (3) on the right-hand side.

Remove:

• the holder for the battery cover, by removing the two nuts in the front edge of the holder and the screw in its rear edge.
• the battery cover.
• the battery negative lead.
• the battery, or move the battery to facilitate access.

Applies to cars with lining mats with four perforations

• Remove the perforated sections (3) from the lining mat.

Applies to cars with lining mats with one perforation

• Remove the lining mat.

Applies to all cars

• Remove the nuts (1) for the bumper.
• Separate the connector (2) for the antenna.

Illustration A applies to cars with mudflaps

• Carefully drill out the rivets for the mudflap. Use a Ø6 mm (1/4") diameter drill bit.
• Remove the mudflaps.

Illustration B applies to all cars

• Carefully drill out the rivet (2) underneath the bumper. Use a Ø6 mm (1/4") diameter drill bit.
• Remove the screw (1).

Примечание: Do not damage any of the plastic components.

Applies to all cars

• Raise the car.
• Remove the rear wheels.

Applies to cars with clips

• Remove the clips underneath the bumper cover by pressing in the centre of the clips until a click is heard. The clips shall be re-used.
• Pull the bumper backwards slightly. Bend out the sides (2) so that they detach from the mounting (1). Continue to pull backwards until the bumper detaches completely.
• Place the bumper on a clean underlying surface that will not damage the paint.

Illustration A applies to the left-hand side

Remove:

• the rivet (1) on the bracket (2) for the silencer. Use cutting nippers
• the screws (3) on the bracket.
• the bracket by detaching the rubber mounting (4). The bracket shall not be re-used.

Illustration B applies to the right-hand side

• Remove the screws (1). Remove the bracket (2). The bracket shall not be re-used.

• Install masking tape on the outside of the bumper cover to avoid damage from the base of the saw.
• Cut along the inside of the flange (1), on the underside of the bumper cover so that the flange remains in the bumper cover.
• After cutting, smooth off the edges using a file.

Illustration A shows the assembly of the tow hitch kit.

Illustration B shows the assembly of the brackets

Illustration C shows installation of the rubber mountings for the exhaust system

Illustration D shows how to bend the heat deflector plate

Illustration E shows the assembly of the cross member and the brackets

• Clean away any underseal and dirt from the surfaces between the towbar kit and the bodywork.

Carry out according to image B on both sides, (the right-hand side is illustrated)

• Install the screws (7, 8) from underneath the brackets (4:1, 5:1, 9:1), including the sleeves (6). Tighten by hand. The arrows on the brackets (4:1, 5:1, 9:1) must point in towards the centre of the car.

Carry out according to images C and D

• Install the heat deflector plate (2) using the screw (1) loosely.
• Bend the heat deflector plate using a screwdriver, as illustrated.
• Tighten the screw.
• Reinstall the rubber mounting (3) for the silencer. Use normal soap to facilitate installation.

Carry out according to image E

• Insert the member (1) between the brackets (4:1, 5:1) and centre around the holes.
• Install the screws (2) and washers (16) from the underneath of the bracket (5), and the nuts (3) from above, but do not tighten.

Carry out according to image A

• Check that the distance between the member (1) and the spare wheel well is 10 mm (25/64") and center the tow hitch against the car.

Carry out according to image B on both sides (the right-hand side is illustrated, the holes are then on the left-hand side)

• Tighten the screws (7). Tighten to 79 Nm (59 lbf.ft.)
• Tighten the screws (8). Tighten to 120 Nm (90 lbf.ft.)

Carry out according to image E

• Tighten the screws (2) and the nut (3) to 136 Nm (102 lbf.ft.).

Carry out according to image B

• Wait at least five minutes, so that it has time to set. Then tighten the screws (8) a quarter turn(angle tighten 90°) on both sides.

Примечание: Torque tightened screws and nuts that have been removed must not be re-used.

Applies to all markets

• Underseal the car (in Sweden only after the state roadworthiness inspection).

Applies to all cars

• If the guide lugs (3) and clips (4) have loosened, reinstall them.
• Reinstall the bumper by pressing it forwards. Ensure that the four screws protruding from the bumper align with the holes in the car. Before the bumper is completely installed, slide the top edge (1) into the grooves. Then slide the bumper fully in.
• Check that the guide lug (3) and clip (4) are centred with the hole in the wheel arch lining.

• Tighten the screw (1) on both sides.
• Rivet (2) in the bumper in the lower edge of the wheel arch.

Applies to cars with clips

• Reinstall the clips underneath the bumper. Ensure that the clip locks are in the normal position.

Applies to all cars

• Reinstall the nuts. Tighten the nuts. Tighten to 18 Nm (13.5 lbf.ft.).
• Plug in the antenna's connector.

Applies to cars with mudguards

• Rivet the mudflaps into place, see step en-GB0900c8af8289bd0a#KC01754636.

Applies to all cars

• Reinstall the wheels and tighten the screws alternately. Tighten to 110 Nm (83 lbf.ft.).

Applies to cars with seal with four perforations (see step )

• Install the rubber tabs from the kit over the four exposed screws as follows:Align the rubber tabs (1, 4) edge to edge with the lining matCompress the rubber tab (2) slightly to align in the cut-outAlign the rubber tab (3) so that the lower edge is edge to edge with the lining mat. Cut off the section protruding over the lining mat. Do not cut off too much.

Applies to cars with seal with one perforation (see step )

• Install a new lining mat.

• If necessary, cut away the area (1) around the screw heads, so that the screws are accessible.

• Install the connecting rod (13) with sleeves (14), screws (15) and nuts (16) together with trailer connector with bracket (17) and the safety cable bracket (21) from the kit.Fit them horizontally. The screws are inserted from the left-hand side with the trailer connector with bracket and the safety cable's bracket located in the rear hole, see kit illustration on page 2.

Примечание: Tighten the bracket with the trailer connector so that the bracket does not catch the lower edge of the bumper.
- Tighten the screws to 65 Nm (49 lbf.ft.). Wait at least five minutes, so that it has time to set. Then angle tighten 90°.

• Install the cable harness connector for the towbar according to step 1 in the appropriate Installation Instructions.
• Install the cable harness for the towbar according to step 2 onwards in the appropriate Installation Instructions.

• Install the towball on the connecting rod with the intended screws and nuts from the kit. The nuts must be on the inside.
• Tighten the towball, tighten to 195 Nm (144 lbf.ft.).

Внимание: The nuts for the towball may only be used once.

• Turn the ignition key to position II.

Reinstall:

• the battery negative lead
• the battery cover and holder
• the side panel in the cargo compartment
• the storage cover and the floor hatch
• the floor carpet

• Remove the protective tape from the bumper.