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FITTING INSTRUCTION
16
14
B
11
14
17
8
3
2
Fig. 1
This
towbar
is
designed
MERCEDES 190, 4 doors (W201), produced since 10.1988 till 08.1993, catalogue no. D04
and is prepared to tow trailers max total weight 1500 kg and max vertical load 75 kg.
Torque settings for nuts and bolts (8,8):
M 8 - 25 Nm
M 10 - 55 Nm M 12 - 85 Nm M 14 - 135 Nm
After install the towbar you should get adequate note in registration book (at authorised
service station).The car should be equipped with:
Indicators
Tow mirrors
After 1000km check all bolts and nuts. The ball of towbar must be always kept clear and
conserve with a grease.
The instruction of the assembly
1.
Disassemble a bumper together with its reinforcement.
2.
From reinforcement disassemble handles (not used any more), see fig. 3.
In bottom part of reinforcement (in axis) saw out fragment dimension 70x45mm – in this
3.
place will be ball brackets of the towbar (see fig. 3).
In upper part of the reinforcement drill holes using bit ø18,5mm (see fig. 3) to get
4.
dimension 1110mm. Fix angle with nut (pos. 8) see fig. 3. Use original bolts M10.
Clamp mark
in acc. with
ISO
PN
1
L
Left directional lights
2
+
Rear fog lights
5
3
31
Ground
4
R
Right directional lights
5
58R
Right side parking lights
6
54
Stoplights
15
7
58L
Left side parking lights
7
17
9
1
4
17
11
13
14
12
8
17
to
assembly
in
following
NOTE
5.
In the bumper cut out fragment 55x60mm (see fig. 2), for better orientation cut on internal
side. Central part of
cutting element will be
Cables joining
factory marked point in
the axis of the bumper.
6.
To the in this way
prepared
main bar of the towbar
(pos. 1). For that use
bolts M8 after handles
disassembly and nuts
M8 are supplied with
towbar (pos. 24). If You
6
will feel over-stress on
the reinforcement use
additional
A
(pos.
accessories.
In rear wall of the car's
7.
body drill two holes
using bit ø12mm (find
original
10
spacing 1110mm.
15
8.
A bumper together with
main bar of the towbar
fix to a car:
cars:
- protruding bolts M10
from main bar (pos. 1)
put through drilled holes in rear wall of a car's body,
- inside a trunk, on protruding bolts put brackets: pos. 5 – left side and pos. 4 – right side,
then fix as shown in the figure 1.
9.
Fix the bracket pos. 6: a) remove rubber plug from chassis member in point where
longitudinal member touch cross member; b) put bracket pos. 6 from trunk's side in this
way so holes pos. A of the bracket be at one with holes in right arm (pos. 4), fix using bolts
and fish-plates pos. 9 and 10 as shown in the figure 1.
10. Fix the bracket pos. 7:
a) remove rubber plug from chassis member as on the right side, remove last handle of
muffler fastening and thermal shield over a muffler,
b) through holes pos. B of the bracket pos. 5 drill holes using bit ø11mm,
c) underneath the car fix brackets pos. 5 and 7 through drilled holes using bolts M10x40mm
(pos. 14),
d) through two rest holes in the bracket pos. 7 drill holes using bit ø11mm and fix all using
bolts M10x35mm (pos. 15).
11. Fix tow-ball (pos. 2) with socket plate (pos. 3) using bolts M12x75mm (pos. 12) and
M12x70mm (pos. 13) from accessories. On first fix also socket plate (pos. 3). See figure.
12. Tighten all bolts according to the torque shown in the table.
13. Connect electric wires of 7-poles socket according to the instruction of the car.
(Recommend to make at authorized service station).
14. Complete paint layer damaged during installation.
Fig. 2
BUMPER
towbar
fix
elements
11)
from
drill
ø18.5
dents
with
Factory marked
drill
point
ø18.5
pos. 8
pos. 8
Fig. 3
BUMPER'S REINFORCEMENT
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