FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
FITTING INSTRUCTIONS FOR
VX VY COMMODORE SEDAN & WAGON
2100KG TOW BAR ASSEMBLY
, & VZ
Page 1 of 8
TOOLS REQUIRED:
Torx Head Screw Driver, Scraper (for Deadener Removal), Hot Air Gun, Power Drill, Drill
Bit, Metal Primer, Silicone Or Butyl Sealer, Socket Wrench, Torque Wrench,
No. 20 11.0mm
10.0mm Socket, 16.0mm
Socket.
Part Numbers
VX, VY & VZ Wagon 92143620
VX Sedan 92143620
VY & VZ Sedan 92176684
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
Page 2 of 8
FITTING INSTRUCTIONS FOR
VX VY COMMODORE SEDAN & WAGON
2100KG TOW BAR ASSEMBLY
, & VZ
1. Remove spare wheel cover and spare wheel from rear compartment.
2. Fold side carpets back from rear corners of boot compartment to access nuts securing bumper to
body (sedan only). Refer to Figure 1 View A.
3. Remove nuts (2 places each side, sedan only). Refer to Figure 1 View A.
4. Remove scrivets (4 places for sedan, 6 places for wagon) at upper edge of fascia. Refer to Figure 1.
5. Remove 2 scrivets at lower fascia edge. Refer to Figure 1.
6. Remove screws (4 places each side) securing fascia to rear edge of wheelhouse. Refer to Figure 1
Views B and C.
7. With fascia supported, pull fascia sides outward disconnecting fascia from side supports and slide
rearwards removing fascia. Refer to Figure 1.
8. Remove bolts (2 places each side) securing bumper support beam to brackets. Refer to Figure 1.
9. Remove nuts (2 places each side) securing bumper support beam brackets to vehicle (2 places) and
remove brackets. Refer to Figure 1.
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
Figure 1
Page 3 of 8
1,0 - 3,0 Nm
6,0 - 9,0 Nm
35,0 - 52,0 Nm
50,0 - 80,0 Nm
4
3
2
1
VIEW B
SCREW
(2 PLACES
R & L SIDE)
VIEW
SEDAN ONLY
C
SCREW
(2 PLACES R & L SIDE)
1
VIEW A
1
A
B
SCRIVET
(2 PLACES)
C
REAR BUMPER
SUPPORT BEAM
BUMPER SUPPORT
MOUNTING BRACKET
NUT
(2 PLACES
R & L SIDE)
4
BOLT
(2 PLACES
R & L SIDE)
3
SCRIVET
(4 PLACES SEDAN,
6 PLACES WAGON)
2
NUT
(2 PLACES
R & L SIDE)
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
Page 4 of 8
10. Smear a thin film of grease to bare metal exposed by removal of brackets, to vehicle body and rear
face of bracket to prevent corrosion. Refer to Figure 2 View A.
11. Install spare wheel well brace assembly to underside of spare wheel well using two existing rearmost
weldstuds. Refer to Figure 2 View D.
12. Loosely fit two M10 nuts and washers to weld studs.
13. Install tow bar to 4 beam support studs, refit beam support brackets over tow bar mounting plates, fit
nuts and hand tighten (2 places each side).
NOTE: Brackets must be installed with tab on flange inboard of vehicle refer Figure 2 View B.
IMPORTANT: Due to elongated holes in tow bar mounting plates, tow bar will have 10-15mm
sideways travel on rear of car. Tow bar must be accurately centralised on vehicle to ensure
bumper fascia cutout aligns with tow bar tongue upon reassembly.
14. To centralise bar, first slide bar to extremity of travel to RH side of vehicle and mark position of edge of
RH mounting plate on body. Refer to Figure 2 View B.
15. Slide bar across to extremity of travel to LH side of vehicle and mark RH mounting plate edge position
on body. Refer to Figure 2 View C.
16. Make a central mark between these two lines (this will centre towbar) & reposition towbar to centre
line.
17. Tighten nuts securing beam support brackets and tow bar mount to body, 50 - 80Nm, (2 places each
side). Refer to Figure 2.
18. Fit two M10 bolts and washers to attach tow bar main assembly to spare wheel well brace assembly.
Refer to Figure 2 View E.
19. Tighten M10 nuts securing spare wheel well brace assembly to underbody weld studs, 30 - 40Nm, (2
places).
20. Tighten M10 bolts securing main tow bar assembly to spare wheel well brace assembly, 30 - 40Nm, (2
places).
21. Use spare wheel well brace assembly as a template to drill two 12,5 dia. holes each side of spare
wheel well. Refer to Figure 2 View E.
WARNING : Be sure spare wheel has been removed from spare wheel well before drilling holes.
22. Apply silicone or butyl sealer to holes for water sealing & corrosion protection purposes, 4 places.
23. Install two adhesive backed stud plates from inside spare wheel well, through holes in wheel well and
spare wheel well brace assembly.
24. From underside of vehicle attach flat washers and M12 nuts to stud plate studs, (4 places). Refer to
Figure 2 View E.
25. Tighten spare wheel well brace assembly to stud plate nuts 30 - 40Nm, (4 places).
26. Refit bumper support beam and tighten bolts 35 - 52Nm.
FITTING INSTRUCTIONS FOR
VX VY COMMODORE SEDAN & WAGON
2100KG TOW BAR ASSEMBLY
, & VZ
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
COAT BARE METAL
SURFACES WITH A
THIN FILM OF GREASE
RH SHOWN
VIEW A
SLIDE TOW BAR TO
EXTREMITY OF TRAVEL
IN LH DIRECTION, MARK
LINE ON BODY
MAKE A CENTRAL MARK
BETWEEN THE TWO LINES,
ALIGN TOW BAR EDGE TO
THIS MARK TO CENTRALISE
TOW BAR
VIEW C
1
2
STUD PLATE
(2 PLACES)
30,0 - 40,0 Nm
50,0 - 80,0 Nm
VIEW D
M10 NUT &
WASHER (2 PLACES)
FLAT WASHERS
(2 PLACES R & L SIDE)
1
1
SPARE WHEEL
WELL BRACE
ASSEMBLY.
M12 NUT
(2 PLACES
R & L SIDE)
STUD PLATE
(2 PLACES)
USE SPARE WHEEL WELL BRACE
ASSEMBLY AS A TEMPLATE TO
DRILL 12.5 DIA. HOLES
(2 PLACES EACH SIDE)
VIEW E
1
M10 BOLT &
WASHER (2 PLACES)
TOW BAR
ASSEMBLY
Figure 2
Page 5 of 8
RH SHOWN
SLIDE TOW BAR TO
EXTREMITY OF TRAVEL
IN RH DIRECTION, MARK
LINE ON BODY
RH SHOWN
BRACKET MUST
BE INSTALLED
WITH TAB INBOARD
VIEW B
REAR BUMPER
BEAM SUPPORT
BRACKET
NUT
(2 PLACES
R &L SIDE)
2
PART OF TOW BAR PACKAGE
M10 NUT & WASHER
(2 PLACES)
SEDAN SHOWN,
WAGON SIMILAR
TOW BAR
ASSEMBLY
C
A B
SPARE WHEEL WELL
SUPPORT ASSEMBLY
E
D
M10 BOLT & WASHER
(2 PLACES)
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
27. Before fascia refit, remove tow bar cover from bumper fascia. Refer to Figure 3.
28. Reinstall fascia in reverse to removal procedure.
NOTE:
On wagon, be sure to position fascia correctly over locating tabs on each corner of body, below tail
lights. Refer to Figure 3.
On sedan, align studs on fascia correctly through holes in body, below tail lights.
29. Install tow bar tongue to tow bar assembly using retainer pin and safety clip. Refer to Figure 3. Check "X"
stamp on side of tongue to verify part.
30. Install anti-rattle bolt and nut. Tighten nut 5 - 10Nm. Refer to Figure 3.
IMPORTANT: Anti-rattle bolt and nut must only be used when tow bar is unladen. Remove anti-
rattle bolt and nut when tow bar is loaded.
31. Install the trailer wiring harness as per fitting instructions included in the trailer wiring harness package.
REVERSE PARKING AID.
IMPORTANT:
The Reverse Parking Aid (if fitted) may be affected when a towbar is fitted to the vehicle and
adjustments may need to be performed. Check the Reverse Parking Aid owners manual for
details.
The trailer harness (Refer to Page 8 for Part Numbers) will de-activate the Reverse Parking Aid
when it is connected to a trailer.
If an adaptor is fitted to the trailer harness it must be removed when the trailer is not attached to
the vehicle, or the Reverse Parking Aid will not operate.
32. Clean surface of driver's side B-pillar and apply ADR label. Refer to Figure 3.
Page 6 of 8
FITTING INSTRUCTIONS FOR
VX VY COMMODORE SEDAN & WAGON
2100KG TOW BAR ASSEMBLY
, & VZ
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
Figure 3
Page 7 of 8
WHEN REINSTALLING WAGON
BUMPER, BE SURE TO POSITION
FASCIA CORRECTLY OVER LOCATING
TABS AT EACH CORNER OF BODY.
WAGON ONLY
WIPE SURFACE CLEAN
PRIOR TO APPLICATION
OF ADR LABEL
SEDAN SHOWN,
WAGON SIMILAR
REMOVE TOWBAR COVER
SAFETY CLIP
TOW BAR
TONGUE
NUT M10
ANTI -RATTLE BOLT M10 x 25
(ONLY USE WHEN UNLOADED)
1
RETAINER
PIN
'D' RING
"X" STAMP MARK
ON SIDE OF TONGUE
FD1046
10MAY04
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
DRAFT
DRAFT
NOT INCLUDED IN TOW BAR PACKAGE, BUT AVAILABLE SEPARATELY:
TRAILER WIRING HARNESS - FLAT 7 PIN
TRAILER WIRING HARNESS - ROUND 7 PIN (LARGE PIN)
TRAILER WIRING HARNESS - ROUND 7 PIN (SMALL PIN WITH BACKING PLATE)
PACKAGE - LOAD DISTRIBUTION HITCH (ADJUSTABLE)
TOW BALL ASSEMBLY (CHROME)
TOW BALL COVER
Page 8 of 8
FITTING INSTRUCTIONS FOR
VX VY COMMODORE SEDAN & WAGON
2100KG TOW BAR ASSEMBLY
, & VZ
PARTS LIST
PARTS LIST
92176684 TOWING KIT, 2100 KG FOR VY/VZ SEDAN. 1
92162955 WELDED TOW BAR ASM INCLUDING ANTI RATTLE BOLT. 1
92143965 SMALL PARTS KIT 1
W BRACKET STUD PLATE 2
WASHER M12 4
NUT M12 4
WASHER M10 4
BOLT M10 X 25 2
NUT M10 2
ADR COMPLIANCE STICKER. 1
W BRACKET 1
92037805 HEATSHIELD REAR FLOOR 1
92143924 CENTRE BEARING HEAT SHIELD KIT 1
92145225 TOWBAR TONGUE. 1
92077203 “D” SHACKLE TOW BAR 2
92145220 PIN & CLIP TOW BAR 1
FD1046 FITTING INSTRUCTIONS 1
FD796 PROOF OF WARRANTY CARD. 1
PART NO. DESCRIPTION QUANTITY
92047620 TOW BAR MAIN ASSEMBLY 1
NOT INCLUDED IN TOW BAR ASSEMBLY, BUT MANDATORY TO FIT:
92145281 TOW BAR SUPPLEMENTARY PACKAGE 2100KG, SEDAN 1
92145282 TOW BAR SUPPLEMENTARY PACKAGE 2100KG, WAGON 1
92054275 BRACE ASSEMBLY - SPARE WHEEL WELL 1
STUD PLATE ASSEMBLY 2
NUT M12 4
FLAT WASHER M12 4
BOLT M10 x 25 2
NUT M10 2
FLAT WASHER M10 4
92077203 'D' RING SAFETY SHACKLE 2
BOLT - ANTI-RATTLE M10 x 25 1
NUT - ANTI-RATTLE M10 1
ADR LABEL 1
92140089 KIT - SHOCK ABSORBER SUPPERLIFT SEDAN 1
92140139 KIT - SHOCK ABSORBER SUPPERLIFT WAGON 1
FD966 TOW BAR FITTING INSTRUCTION BOOKLET 1
FD796 WARRANTY CARD 1
92145225 PACKAGE TOW BAR TONGUE 1
92145220 PIN & CLIP 1
NOTE: Contents described in parts list supplied with each supplementary package.
PART NO. DESCRIPTION QUANTITY
NOT INCLUDED IN TOW BAR ASSEMBLY, BUT MANDATORY TO FIT:
92145281 TOW BAR SUPPLEMENTARY PACKAGE 2100KG, SEDAN 1
92145282 TOW BAR SUPPLEMENTARY PACKAGE 2100KG, WAGON 1
NOTE: Contents described in parts list supplied with each supplementary package.