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Installation instructions:
Disassemble the rear bumper and the reinforcement. The bumper reinforcement is no longer required after
1.)
installation of the towing device. The bumper reinforcement should, however, be reassembled to the vehicle if
the towing device is disassembled at a later date.
2.)
Loosely attach the base part 1 on the left and right-hand side at point "a" and "b" using the M10x1.25x30
bolts and 10.5x20x2 washers.
Attention: M8 nuts may be required for certain vehicles. If this is the case, it is possible to order a set of
M8x30 (8.8) bolts with 8.5x24x2 washers under the order no.: 906 270 650 002. The tightening torque at point
"a" for the M8x30 bolts is then 20 Nm.
Attention: Vehicles built March 2008 and after do not have the chassis bores at "b". In this case, transfer /
mark the bores "b" in the trailer hitch to the chassis. Dismount the trailer hitch and cut the marked bores "b"
only into the rearmost plate of the dual-layer rear plate, ø14 mm (see figure Y). The front plate already has a
bore. Be extremely careful when performing this work in order to avoid damage to the front plate and the nuts.
Remove the burrs from the bore and vacuum off the filings.
Pre-treat the surfaces with a cloth lightly soaked with DX380 detergent by PPG (or equivalent). Then apply
30-40 μm layer of anti-corrosive. For this purpose, use STANDOX-EP primer (grey) by Dupont or IVIEPOX
458515 (brown) by PPG. Dry the anti-corrosive primer for approx. 10 minutes with a blow-drier at 80°-90°.
Then paint the surfaces with the original vehicle paint or dry with an infrared lamp for approx. 15 min. at 130
°C.
Observe manufacturer specifications and environmental standards.
3.)
Loosely attach the supports 2 and 3 to the base part 1 at point "d" using the M12x35 bolts, 12.5x30x3
washers and M12 nuts. Now loosely attach the supports 2 and 3 to the chassis beam at point "c" using the
13x26x30 wedge discs, 12.5x30x3 washers, M12x135 bolts and M12 nuts.
Attention: Vehicles (e.g. version XL) with a tail section of 1380 mm (distance from rear axle to the end of the
vehicle) do not have bore holes in the chassis beam at point "c". In this case, additional fixing elements are
required. The fixing elements can be ordered (order no. 906 270 650 003). The supports 2 and 3 should then
be installed at point "c" according to the additional installation instructions.
4.)
Insert the shackles 6 through the lower apertures in the chassis beam (the square nuts have to face upwards)
and allow them to engage in the apertures. Now loosely attach the bracket 4 to the chassis beam at point "f"
using the M12x60 bolt and 12.5x30x3 washer. Loosely attach the bracket 5 to the chassis beam at point "e"
using the M12x45 bolt and 12.5x30x3 washer.
Loosely attach the brackets 4 and 5 as well as the supports 2 and 3 to the base part 1 at point "g" using the
5.)
M12x50 bolts, 12.5x30x3 washers and M12 nuts.
Align the towing device and tighten the M10 bolts at point "a" with a tightening torque of 40 Nm. Now tighten
6.)
the M12 bolts at point "g" with a tightening torque of 10 Nm. Now tighten the M12 bolts with a tightening
torque of 65 Nm in the following order "c", "d" "e", "f", and "g".
Saw the hatched area out of the underside of the bumper as indicated on diagram X. The line "Y0"
7.)
corresponds to the middle of the vehicle. Assemble the sawn out bumper to the vehicle. Also use the M6x20
bolts, 6.4x24x2 washers and M6 nuts on the left and right-hand side at point "p".
306 271 691 101 - 005
GB
Subject to alteration.
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