gdw 1403 Instructions De Montage page 5

Mazda MPV Karakuri
2003 - ....
Ref. 1403
Fitting instructions
1) Disassemble the bumper and the exhaust in the rear. Remove the inner coating and the plastic side coating in the
trunk. Permanently remove the metal buffer beam at the back of the vehicle (retain the original nuts). Sharp the
suspension of the exhaust and treat the cutting surfaces with a rust preventing agent.
2) Place the mounting pieces (-r) and (-v) with (A) against the bottom of the chassis beam matching the provided
screw thread holes, insert the bolt but do not tighten. Place the side pieces by leaving (D) match the provided
drilling in the rear at the end of the chassis beam. Drill these points (D) together with points (B) and (C)
perpendicularly through with ø10,5mm till in the trunk, enlarge the drillings of points (D) in the trunk till ø17mm
and insert the tubes (-n) through the trunk in the chassis beam. Remove the side pieces and insert on the provided
drillings, at the bottom of the chassis beam, on the points (B) and (C) of the tow bar, the filling pieces (-o) and (-p)
in the chassis beam. Replace the side pieces (-r) and (-v) against the washers by points (A). Insert the bolts by (B),
(C) and (D) through the trunk, place the plates (-f) by (B) and (C) on the made drillings and the washers by (D).
Do not tighten all bolts yet.
3) Assemble now the mounting pieces (-u) and (-t) with (E) on the provided bolts where the metal buffer beam was
fixed (use therefore the original bolts M10). Points (G) match points (G) of the side plates (-r) and (-v). Points (F)
match the provided drillings in the back of the cross-beam, these are sealed with a rubber cap which has to be
removed. Drill these points through till in the trunk and enlarge the drillings in the trunk till ø17mm. Insert the
tubes (-m) in the drillings in the trunk together with the plates (-k) and the bolts. Do not tioghten the bolts yet.
4) Place the tow bar between the mounting pieces (-u) and (-t) till points (H) match those of the mounting pieces.
Insert the bolts and screw everything firmly on (according to tension).
5) Re-assemble the bumper and the exhaust on the vehicle. Refix the exhaust on point (K) of the tow bar.
6) Assemble (*) together with the socket plate holder and the security shackle, tighten everything firmly.
Composition
1 tow bar reference 1403
1 ball T45M006
2 bolts M12x65 - DIN931
2 bolts M12x60 - DIN931
4 security nuts M12 - DIN985
2 mouting tubes T45
2 mounting pieces T45
1 security shackle (-s)
1 socket plate P04
2 bolts M10x35x1/25 - DIN961
14 security washers M10-DIN128A (A-B-C-D-F-G) 4 security washers M12 - DIN128A
4 washers 40x35x12x4mm
12 nuts M10 - DIN934
Note
Please consult your cardealer or owners manual for the maximal permissable towing mass.
Remove any bitumen coating on the fastening position for the tow bar.
When drilling, be carefull not to damage any brake lines, electrical wiring or fuel lines.
(*-*') 4 bolts M10x130 - DIN931
(*') 2 tubes (-p) 24x4x97mm
(*) 2 tubes (-o) 24x4x102mm
(*-*') 2 bolts M10x120 - DIN931
(*) 2 tubes (-n) 16x2x90mm
(*-*') 2 tubes (-m) 16x2x65mm
(*') 2 bolts M10x90 - DIN931
(*) 4 bolts M10x30 - DIN933
(A) 4 bolts M12x35 - DIN933
(A-D) 2 mounting pieces (-r and -v)
(B-C-D-F-G) 2 mounting pieces (-u and -t)
All bolts and nuts : quality 8.8
(B-C)
(B)
(C)
(D)
(D)
(F)
(F)
(G)
(H)
(H)
(G)
(H)