FD1005

05NOV04

Reproduction in whole or part

prohibited without written approval

HOLDEN LTD

Division of HOLDEN Ltd ACN 006 893 232

FITTING INSTRUCTIONS FOR

TT ZAFIRA 1000kg TOW BAR PACKAGE

Part No. 92143916

TOOLS REQUIRED:

TORX HEAD SCREW DRIVER (TORX BIT No. 20)

SCRAPER (FOR DEADENER REMOVAL)

HOT AIR GUN

POWER DRILL

DRILL BIT, PILOT

HOLE SAW, 24.0mm DIA.

METAL PRIMER

SILICONE OR BUTYL SEALER

SOCKET WRENCH

TORQUE WRENCH

SOCKETS: 8mm, 13mm & 16mm

Page 1 of 5

FD1005

05NOV04

Reproduction in whole or part

prohibited without written approval

HOLDEN LTD

Division of HOLDEN Ltd ACN 006 893 232

FITTING INSTRUCTIONS FOR

TT ZAFIRA 1000kg TOW BAR PACKAGE

SCREW

2 PLACES

SCREW

10 PLACES

BUMPER FACIA

BEAM NUTS

6 PLACES

FACIA

1. Open rear hatch and place vehicle on a 2 posted

hoist for eased of fitment.

2. Remove 2 Torx head screws (Screwdriver-No. 20

bit) and washers retaining rear facia in the wheel

house area. Right and left sides. Refer Figure 2.

NOTE: If the vehicle is fitted with mud deflectors, the

lower screw requires a 8.0mm socket for removal.

3. Remove 10 Torx head screws (Screwdriver No. 20

bit) and washers retaining the upper and lower of the

rear of the facia.

Remove the rear facia. Refer Figure 3.

4. Remove 4 nuts (13mm socket) retaining the rear

bumper facia beam. Remove and discard bumper

facia beam. Refer Figure 4.

FIGURE 1

FIGURE 2

FIGURE 3

FIGURE 4

Page 2 of 5

FD1005

05NOV04

Reproduction in whole or part

prohibited without written approval

HOLDEN LTD

Division of HOLDEN Ltd ACN 006 893 232

FITTING INSTRUCTIONS FOR

TT ZAFIRA 1000kg TOW BAR PACKAGE

5. Remove grommets from rear end inner panel - 4

places and discard. Drill a pilot hole centrally in the

recess in the rear end outer panel - 4 places.

Enlarge the hole in the rear end outer pane , using a

24.0mm hole saw - 4 places. Debur holes and

vacuum up all metal particles. Coat bare metal with

corrosive protective paint. Refer Figure 5.

6. If present, remove two screws from the transport

bracket, remove and discard bracket, screws and U-

nuts. Refer Figure 6.

7. Using a hot air gun and scraper, remove deadener

from the rear longitudinal, LHS only. Coat any bare

metal with corrosive protective paint. Refer Figure 7.

8. Install the M6 U-nut in the LHS and RHS

longitudinal. Refer Figure 8.

FIGURE 5

FIGURE 6

FIGURE 7

FIGURE 8

Division of HOLDEN Ltd ACN 006 893 232

24.0mm DIA.HOLE

IN THE REAR END

OUTER PANEL

4 PLACES

REMOVE GROMMET

FROM HOLE IN THE

REAR END INNER PANEL

4 PLACES

TRANSPORT

BRACKET

DISCARD

SCREW DISCARD

SCREW

DISCARD

U-NUT

M6 U- NUT

Page 3 of 5

FD1005

05NOV04

Reproduction in whole or part

prohibited without written approval

HOLDEN LTD

Division of HOLDEN Ltd ACN 006 893 232

FITTING INSTRUCTIONS FOR

TT ZAFIRA 1000kg TOW BAR PACKAGE

9. Position the LH reinforcement bracket to align with

the 24.0mm dia. holes in the rear end outer panel

and the existing holes in the rear end inner panel

and fix with a M6 hex head screw. Tighten to a

torque of 12Nm. Refer Figure 9.

10. Position the RH reinforcement bracket to align with

the 24.0mm dia. holes in the rear panel and fix with

by reusing the existing 8.0mm dia. hex head screw.

Tighten to a torque of 12Nm. Refer Figure 10.

11. Fit bolts to tow bar and install spacer tubes, 4 places

Refer Figure 11.

12. Offer up the tow bar to the rear end panel and install

the bolts and the spacer tubes through the 24.0mm

dia. holes to align with the R and LH hand

reinforcement weld nuts. Tighten bolts to specified

torque. Refer Figure 12.

NOTE: Tow bar tongue may be removed to aid

fitment. Refit tow bar tongue and tighten to specified

torque.

Attach D shackle to tow bar tongue.

FIGURE 9

FIGURE 10

FIGURE 12

FIGURE 11

REINFORCEMENT

BRACKET - LH

REINFORCEMENT

BRACKET - RH

ALIGN WELD NUTS

WITH EXISTING

HOLES IN REAR

END INNER PANEL

EXISTING

SCREW

M6 SCREW

12 Nm

44 Nm

80~90 Nm

M6 FLAT

WASHER

ALIGN WELD NUTS

WITH EXISTING HOLES

IN REAR END INNER

PANEL

SPACER

TUBES

2 PLACES R/L

M10 BOLT

2 PLACES R/L

M10 SPRING

WASHER

2 PLACES R/L

M16 BOLT

M16 SPRING

WASHER

TONGUE

M10 BOLT

TOW BAR

ASM.

D SHACKLE

Page 4 of 5

FD1005

05NOV04

Reproduction in whole or part

prohibited without written approval

HOLDEN LTD

Division of HOLDEN Ltd ACN 006 893 232

FITTING INSTRUCTIONS FOR

TT ZAFIRA 1000kg TOW BAR PACKAGE

Page 5 of 5