FITTING INSTRUCTIONS FOR

WH STATESMAN & CAPRICE

1600KG TOW BAR KIT

Part Number 92144169

Page 1 of 8

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1600KG TOW BAR FITTING INSTRUCTIONS

REAR BUMPER BAR SUPPORT BEAM & BRACKETS REMOVAL

Fold side carpets back from rear corners of boot compartment to access nuts securing bumper to body

refer figure 1, view A.

Remove nuts (2 places each side) refer figure 1, view A

Remove 4 scrivets at upper edge of facia, refer figure 1.

Remove 2 scrivets, lower facia edge, refer figure 1.

Remove 8 screws, facia to rear edge of wheelhouse, refer figure 1, views B and C.

With facia supported, pull facia sides outward disconnecting facia from side supports and slide rearwards

removing facia, refer figure 1.

Remove 4 bolts securing bumper support beam to brackets, refer figure 1.

Remove 4 nuts securing bumper support beam brackets to vehicle (4 places) and remove brackets,

refer figure 1.

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1,0 - 3,0 Nm

6,0 - 9,0 Nm

35,0 - 52,0 Nm

50,0 - 80,0 Nm

VIEW B

SCREW

(2 PLACES

R & L SIDE)

VIEW A

NUT

(2 PLACES

R & L SIDE)

Page 3 of 8

HOLDEN SERVICE PARTS OPERATIONS

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Figure 1

NUT

(2 PLACES

R & L SIDE)

REAR BEAM

MOUNTING BRACKET

REAR BUMPER

SUPPORT BEAM ASM.

SCRIVET

(2 PLACES)

BOLT

(2 PLACES

R & L SIDE)

SCRIVET

(4 PLACES)

VIEW C

SCREW

(2 PLACES)

R & L SIDE

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TOW BAR INSTALLATION

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 figure 2, view A.

Install spare wheel well support assembly to underside of spare wheel well using two existing rearmost

weldstuds, refer figure 2, view D.

Loosely fit two M10 nuts and M10 flat washers to weld studs.

Install tow bar to 4 beam support studs, refit beam support brackets over tow bar mounting plates, refit

existing nuts and hand tighten (4 places).

NOTE : Brackets must be installed with tab on flange inboard of vehicle refer figure 2, view B.

Loosely fit two M10 bolts and M10 flat washers to attach tow bar main assembly to spare wheel well support

assembly.

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

facia cutout aligns with tow bar tongue upon reassembly.

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 figure 2, view B.

Slide bar across to extremity of travel to LH side of vehicle and mark RH mounting plate edge position

on body, refer figure 2, view C.

Make a central mark between these two lines (this will centre towbar) & reposition towbar to centre line.

Tighten nuts securing beam support brackets and tow bar mounts to body, 50 - 80Nm (4 places), refer figure 2.

Tighten nuts securing spare wheel well support assembly to underbody weld studs, 30 - 40Nm, (2 places)

Tighten bolts securing main tow bar assembly to spare wheel well support assembly, 30 - 40Nm, (2 places)

Refit bumper support beam, and tighten bolts 35 - 52Nm.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

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30,0 - 40,0 Nm

50,0 - 80,0 Nm

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

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

VIEW D

COAT BARE METAL

SURFACES WITH A

THIN FILM OF GREASE

RH SHOWN

VIEW A

NUT M10

(2 PLACES)

WASHER M10

(2 PLACES)

WASHER M10

(2 PLACES)

SPARE WHEEL WELL

SUPPORT ASSEMBLY

(ENSURE CORRECT

ORIENTATION)

VIEW E

1BOLT M10

(2 PLACES)

TOW BAR

ASSEMBLY

Figure 2

Page 5 of 8

HOLDEN SERVICE PARTS OPERATIONS

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REAR BUMPER

BEAM SUPPORT

BRACKET

NUT

(2 PLACES

R &L SIDE)

PART OF TOW BAR PACKAGE

BOLT M10

(2 PLACES)

WASHER M10

(2 PLACES)

WASHER M10

(2 PLACES)

NUT M10

(2 PLACES)

TOW BAR

ASSEMBLY

A B

SPARE WHEEL WELL

SUPPORT ASSEMBLY

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Clean surface of driver's side B pillar and apply ADR label, refer figure 3.

Install trailer wiring harness as per fitting instructions included in trailer wiring harness package.Refer page 8.

bolt and nut when tow bar is loaded.

IMPORTANT : Anti-rattle bolt and nut must only be used when tow bar is unladen. Remove anti-rattle

Install anti-rattle bolt and nut. Tighten nut 5 - 10Nm

For installation of tow bar tongue package, heat shields and heat shields spare wheel package, refer

parts list , page 8.

NOTE : Align studs on facia correctly through holes in body, below tail lights.

Reinstall facia in reverse to removal procedure.

hitch mounting tube, refer figure 3.

Before facia refit, knock out section in centre of bumper facia to allow protrusion of bar

26.

25.

24.

23.

22.

21.

Page 6 of 8

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NOTE: Once tow bar installation is complete, place Fitting Instruction booklet in glove box of vehicle.

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Figure 3

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WIPE SURFACE CLEAN PRIOR

TO APPLICATION

BUMPER FACIA

KNOCKOUT

5 - 10 Nm

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ANTI -RATTLE BOLT M10 x 25

(ONLY USE WHEN UNLOADED)

'D' RING

NUT M10

ADR LABEL

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PART NO. DESCRIPTION QUANTITY

92059987 TOW BAR PACKAGE CONSISTS OF:

92076517 TOW BAR MAIN ASSEMBLY 1

NUT M10 2

FLAT WASHER M10 4

BOLT M10 x 25mm 2

BOLT - ANTI RATTLE - M10 x 25mm 1

NUT - ANTI RATTLE - M10 1

92054276 SUPPORT ASSEMBLY - SPARE WHEEL WELL 1

92077203 'D' RING SAFETY SHACKLE 1

ADR LABEL 1

FD907 TOW BAR FITTING INSTRUCTION BOOKLET 1

FD796 WARRANTY CARD 1

92047624 PACKAGE - TOW BAR TONGUE 1

92037805 HEAT SHIELDS, SPARE WHEEL WELL 6

92143924 PACKAGE - HEAT SHIELD, CENTRE BEARING 1

1600 KG TOW BAR KIT

FOR WH STATESMAN & CAPRICE

Part number 92144169

PARTS LIST

SMALL PARTS KIT

COVERBALL 92140106

92143023

92140068 TOW BALL ASSEMBLY (CHROME)

92140126 PACKAGE - LOAD DISTRIBUTION HITCH (FIXED)

92140148 TRAILER WIRING HARNESS - ROUND 7 PIN (SMALL PIN WITH BACKING PLATE)

92140147 TRAILER WIRING HARNESS - ROUND 7 PIN (LARGE PIN)

92140088 TRAILER WIRING HARNESS - FLAT 7 PIN

NOT INCLUDED IN TOW BAR PACKAGE, BUT AVAILABLE SEPARATELY:

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