Holden - Calias - Workshop Manual - 2006 - 2006

Towbar Fitting Instructions To Suit Holden Ve Omega,Berlina,Calias,SV6 & SS 08-06-ON Part Number QTHD491L Rating 2100 kg Automatic 1600Kg Manual WARNING: 1. Do not, drill, cut, weld or otherwise modify the tow bar. 2. If you are using electric welding on a motor vehicle, always check that the vehicle is not equipped with electronic engine or instrument management equipment. Failure to do so could destroy any onboard computers. If in doubt, check with the vehicle's manufacturer. General: 1. Ensure all hardware items have been included 2. It is recommended that the instructions are read through and completely understood before making any attempt to fit this product. 3. Be wary of any changes to vehicle designs or other accessories that may conflict with the installation of this product. 4. Before drilling ensure that the area is clear of fuel, electrical & other components. 5. All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint. 6. The high tensile fasteners supplied with this product were used to achieve the specified rating. If replacement is required ensure that fasteners of the same rating & quality are used. Contact an authorized Trailboss dealer if further information is required. 7. Ensure that all hardware is fastened to torque list below check fasteners on regular basis. 8. Tow bar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver's door. (See diagram below). 9. Trailboss recommends that you check your tow ball to ensure that it complies with the Australian standards AS 4177.2. 10. PLEASE NOTE: It is advised to remove your lug or tbm when not actually towing so as to produce a clear view of the vehicles registration plate if obscured, and to also provide maximum available departure angle. RECOMMENDED ASSEMBLY TORQUE LISTING Diameter Grade 8.8 Bolt Place load rating sticker inside driver’s door here M6 M8 M10 M12 M16 9.5 Nm 21.7 Nm 43.4 Nm 77.3 Nm 189.8 Nm ENSURE THAT SPRING WASHERS PROVIDED ARE USED WITH ALL FASTERNERS. FOR TOWING PURPOSES ONLY For towing capacity details please refer to vehicle owner’s manual or to the manufacturer. Overloading can void your warranties. Page 1 of 4 THE WORKHORSE OF AUSTRALIA’S TOWBARS Issue Date 3/3/10 Towbar Fitting Instructions To Suit Holden Ve Omega,Berlina,Calias,SV6 & SS 08-06-ON Part Number QTHD491L Rating 2100 kg Automatic 1600Kg Manual Rear luggage compartment & reverse sensors if fitted. 1. Open the rear luggage compartment then remove the spare wheel cover. 2. Remove the rear plastic trim via. a. 4 plastic trim buttons 2 each side b. Then pull in an upwards motion to remove. 3. Remove the left hand side trim panel via. a. 2 plastic trim plugs b. Tabbed tongue on the top edge of the trim being careful not to tear. c. Pull trim to the side repeat for right hand side. 4. Disconnect the rear parking sensors connector if fitted, and then pull through existing hole in trim Rear bumper bar skin & impact beam removal. 5. Remove the rear bumper skin via. a. 2 plastic scrivets & 1 screw from inside the wheel arch each side (3 plastic scrivets if fitted with mud flaps). b. 3 plastic trim buttons from the underside of the bumper bar skin c. Flex out the bar skin from the sides then pull reward to remove d. Place bumper in a secure location to prevent damage e. Remove the impact beam via 4 M 8 nuts 2 each side f. Pull the impact beam rearward to remove retain the beam & M 8 nuts. Removal of impact beam mounting brackets. 6. Remove the impact beam mounts via. a. 4 M10 bolts from the inside the rear luggage compartment see fig1. b. Pull rearward to remove left & right impact beam mount then discard mounts see fig 2. Drill through captive nuts & drill through chassis rails inside boot cavity. 7. From inside boot cavity using existing holes as guide drill captive nuts through 10.5 mm ensure that the thread is completely removed see fig 3. 8. From inside the boot cavity use centre pop mark as a guide drill through top surface on each side 10.5mm see fig 4. Page 2 of 4 THE WORKHORSE OF AUSTRALIA’S TOWBARS Issue Date 3/3/10 Towbar Fitting Instructions To Suit Holden Ve Omega,Berlina,Calias,SV6 & SS 08-06-ON Part Number QTHD491L Rating 2100 kg Automatic 1600Kg Manual Fitment of tow bar to chassis rails. 9. Unbolt rear muffler from hanger via 2 M8 bolts each side of hanger (note twin mufflers for SV6 & SS models). 10. Remove the rear most tek screw fastening the exhaust heat shield to aid fitment (note SV6 & SS models have twin mufflers. 11. Offer tow bar to chassis rails so to align the captive nuts on tow bar mounting arms with the existing holes see fig 4. 12. Some force may be required to slide the bar up the chassis rails 13. Fit top loose plates M10 x 40 bolts with spring washers loosely inside boot cavity see fig 5. 14. Fit M10 x 40 bolts with flat & spring washers supplied to captives on the underside of the chassis rails loosely see fig 6. 15. Fit M12 x 40 bolts with loose plates & spring washers to the forward most mount on the under side of the chassis rails see fig 6, tighten fasteners to the torque listing on page 1. Refit the impact beam 16. Place impact beam over the M 8 x 35 bolts that petrude through the rear face of the tow bar side arms & fasten with original M8 nuts that fastened the impact beam retained in step No 5 e. tighten to torque listing on page 1. Cut rear bumper skin 17. Using a small pilot drill to pierce through the bar skin to allow a small blade from a saw or similar device cut around the outline of the Holden factory indent in the rear bar skin see fig 7. 18. Clean all raw edges with a small file to ensure the neatness of the finished cut. Page 3 of 4 THE WORKHORSE OF AUSTRALIA’S TOWBARS Issue Date 3/3/10 Towbar Fitting Instructions To Suit Holden Ve Omega,Berlina,Calias,SV6 & SS 08-06-ON Part Number QTHD491L Rating 2100 kg Automatic 1600Kg Manual Refit the rear bumper bar skin 19. Carefully maneuver the bumper bar skin with the centre bumper cut out over the hitch box ensuring not to damage the bar skin. 20. Then refit the bumper in the reverse of steps 5 d to 5 a. Refit the rear muffler & heat shield. Refit the rear muffler & rear heat shield via the 2 M 8 bolts & tek screws as detailed in steps 9 & 10 Refit the rear luggage compartment & reverse sensors if fitted. Refit the trim on the inside of the rear luggage compartment in the reverse of step 4 through to step 1. Page 4 of 4 THE WORKHORSE OF AUSTRALIA’S TOWBARS Issue Date 3/3/10 Wiring Loom Fitting Instructions To Suit Holden VE / WM Commodore Sedan & Wagon Part Number 100007-WL Wiring Loom Installation Instructions Holden VE / WM Commodore Sedan & Wagon Part No: 100007-WL Tail Harness Length Required: 1800mm ECU Required: 04826 RPA Override Switch Part No: 04848 (If Aftermarket RPA’s Fitted) Wiring Loom Installation Time: Approx 30 Mins Sedan – Page 2 Wagon – Page 3 Page 1 of 3 Issue Date 23-05-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit Holden VE / WM Commodore Sedan & Wagon Part Number 100007-WL This section is for Sedan vehicles only. For Wagon vehicles please refer to Page 3. 1. In the luggage compartment, remove all trims required to gain access to the tail lights. 2. Locate the RHS 12-way tail light connectors. Disconnect the tail light connectors and patch the Trailer Patch Harness (P/No: 100007-WL) connectors in between the tail light connectors. 3. Secure the Trailer Patch Harness ground ring terminal located near the RHS rear wheel arch area using a tech screw (not supplied). 4. Connect the Trailer Patch Harness (P/No: 100007-WL) 12-way female ECU connector into the ECU (P/No: 04826) and secure the ECU onto the vehicle harness at the wheel arch area using cable ties (not supplied). 5. Drill out a Ø31mm hole into the rear RHS area of the spare tyre well. 6. From outside of the vehicle, route the Tail Harness (tail length 1800mm) into the bumper towbar cut out and into the spare wheel well via the drilled out hole. 7. Mount the trailer socket on to the towbar socket mounting plate using M4 fasteners (not supplied). 8. Inside the spare wheel well, route the Tail Harness all the way through and adjust the Tail Harness grommet into position. Secure the Tail Harness grommet into place with a cable tie (not supplied). 9. Connect the 8-way male Tail Harness connector to the 8-way female Trailer Patch Harness connector. 10. Test the Trailer socket using a light board or multi-meter. 11. Secure all harnesses using cables ties (not supplied). 12. Re-fit all removed parts and secure all fasteners. 13. Place the instructions in the glove box after fitment. Page 2 of 3 Issue Date 23-05-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175 Wiring Loom Fitting Instructions To Suit Holden VE / WM Commodore Sedan & Wagon Part Number 100007-WL This section is for Wagon vehicles only. For Sedan vehicles please refer to Page 2. 1. In the luggage compartment, remove the floor carpet. 2. Remove the rear trim. 3. Remove the luggage compartment RHS rear side trim by removing the cargo strap hooks and the lower clip. 4. Remove the RHS foam spacer. 5. Dislodge the RHS rear side trim by first removing any clips or fasteners. 6. Locate the 12-way tail light connectors. 7. Disconnect the tail light connectors and patch the Trailer Patch Harness (P/No: 100007WL) connectors in between the tail light connectors. 8. Secure the Trailer Patch Harness ground ring terminal using a tech screw as shown. 9. Connect the Trailer Patch Harness 12-way female ECU connector into the ECU (04826). 10. Apply double sided tape to the ECU and adhere it to the vehicle sheet metal on the RHS of the luggage compartment wheel arch. 11. Using a drill and a Ø31mm hole saw/step drill, drill a hole into the spare tyre well. 12. File any rough or sharp edges and spray on rust inhibitor. 13. From outside of the vehicle, route the Tail Harness (tail length 1800mm) into the bumper towbar cut out and into the spare wheel well via the drilled out hole. 14. Mount the trailer socket onto the towbar socket mounting plate using M4 fasteners (not supplied). 15. Inside the spare wheel well, route the Tail Harness all the way through and adjust the Tail Harness grommet into position. 16. Secure the Tail Harness grommet into place with a cable tie (not supplied). 17. Connect the tail harness 8-way connector to the trailer harness mating 8-way connector. 18. Test the trailer harness function using a light board or multi-meter. 19. Secure all harnesses using cables ties (not supplied). 20. Re-fit all removed parts and secure all fasteners, ensuring there are no squeaks or rattles. 21. Place the instructions in the glove box after fitment. Page 3 of 3 Issue Date 23-05-11 Cequent Customer Service Ph: 1800 812 017 Fax: 03 9797 3299 Email: [email protected] Post: PO Box 4050, Dandenong South VIC 3175