Hayman Reese 03257RW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 1 Issue Date: 03-05-19
PRODUCT DETAILS:
Part Number: 03257RW Maximum Towing Bra ed: 1900 kg
ECU Number: 04826 Maximum Towing Unbra ed: 750 kg
Tail Harness Length Required: 1200 mm Maximum Static Ball Load: 100 kg
TBM/Lug Part Number: 21360
Wiring Part Number: 101469-WL
FITTING DETAILS:
Towbar Installation Time: 60 M ns. Vehicle Coding Required: NO
Wiring Installation Time: 30 M ns. RPA Disable/Other: YES
Total Installation Time: 90 M ns. Note:
Bumper Cut Required: Yes •RPA Disable via switch on centre console.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 2 Issue Date: 03-05-19
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
Hayman Reese recommends that nstruct ons are read completely pr or to f tment.
Check all hardware tems have been ncluded refer to assembly d agram.
Please ensure th s towbar s only f tted to veh cle models as per Hayman Reese appl cat on gu de
(www.haymanreese.com.au).
Bumper Cuts
Veh cle and bumper var at ons can and do occur dur ng veh cle manufacture after n t al towbar
des gn. F tment of towbar to veh cle and accuracy of bumper cut must be assessed pr or to any
bumper mod f cat ons made. Incorrect bumper cuts are not covered under Hayman Reese warranty.
NOTE: Bumper cuts need to be approached with care, refer to notes below.
•Bumper centrel ne – where the centrel ne of the bumper needs to be determ ned, the nstaller
must assess centre po nt by measurement of bumper w dth or determ n ng two symmetr cal
reference po nts to g ve centrel ne.
•Bumper edge – To ass st w th accurate bumper cut measurement, reference to the start of the
bumper edge s now be ng commonly used.
oMeasure from bottom edge along bumper and around corner to the 70 mm po nt
(F gure 1).
o
Do not measure from v s ble bumper front of corner, upwards (F gure 2).
Drilling
•For any requ red dr ll ng dur ng nstallat on, ensure that the area s clear of fuel, electr cal & other components that may be
damaged.
• All holes dr lled nto the body panels shall have all burrs & swarf removed then coated w th a su table rust preventat ve pa nt.
Bolts/Fasteners
•Ensure that all hardware s fastened to correct torque as spec f ed n th s f tt ng nstruct on.
•All fasteners suppl ed w th th s product are used to ach eve a spec f ed clamp load ng. If replacement s requ red ensure that
fasteners of the same grade and class are used.
NOTE: Achieving correct torque is critical to proper installation and responsibility of the installer. Towbar failures attributed to
tension issues from over tightening or under tightening are not covered by Hayman Reese warranty.
Product Labels
a. Towbar load rat ng st cker prov ded w th th s product shall be consp cuously located on ns de rear end of the dr ver’s door.
b. Powertra n Control Module (PCM)/Body Control Module (BCM) upgrade warn ng label w ll be prov ded n towbar k t for
veh cles as requ red. Aff x warn ng label n door and owner’s handbook.
WARNING:
Do not, drill, cut, weld or otherwise modify the towbar.
FOR TOWING PURPOSES ONLY - This towbar is designed and tested by Hayman Reese to adhere to ADR 62/02 which provides
only for the expected load demands of towing.
F gure 1
INCORRECT
CORRECT
Place Vehicle PCM/ BCM upgrade
warning label n door AND on front
cover of owner’s serv ce handbook
Place
Load Rating
stic er ns de dr ver’s
door here
F gure 2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 3 Issue Date: 03-05-19
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1 KIA SPORTAGE WELDED ASSY 1 14 PLUG BRACKET 1
2 SIDE ARM ASSY RH 1 15 TEK SCREW 14-20 HEX HD 22mm 4
3 SIDE ARM ASSY LH 1 16 SET SCREW HEX HD M5x20x0.8P 2
4 CHASSIS NUT PLATE ASSY 2 17 NUT NYLON INS LOCKHEX HD M5X0.8P 2
5 BUMPER TAB 2 18 WASHER FLAT M6X12.5X1.2 4
6 SMART KEY ANTENNA BRACKET 2 19 TOWBALL 50MM FLAT CHROME 1
7 M12x1.25 TAP PLATE WITH 300 WIRE 2 20 H.R STICKER 1
8 WASHER PLAIN 1/2X1-1/8X16G 18 21 10mm "D" SHACKLE 2
9 NUT HEX HD M12 X 1.25P G8 6 22 HITCH BOX COLLAR COVER 1
10 SET SCREW M12 - 1.25 x 45mm GR 8.8 6 23 SMART PIN ASSY CLASS 4 - GOLD 1
11 SET SCREW HEX HD M12 X 45 X 1.25P G10.9 6 24 ACRYLIC COMPLIANCE LABEL 1
12 TRAILER BALL MOUNT 1 25 WIRING LOOM 1
13 NUT NYLON LOCK HEX HD M4X0.7P G8 2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 4 Issue Date: 03-05-19
1.
Open ta lgate and remove exposed plast c ta ll ght
tr m cover.
Repeat for other s de
.
2. Remove exposed 2 x Screws secur ng the ta ll ght to
the body.
3. Remove ta ll ght by pull ng rearwards and d sconnect
from w r ng harness.
Repeat for other s de.
4. In l ght cav ty, remove 2 x Scr vets.
Repeat for other s de.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 5 Issue Date: 03-05-19
5. In wheel arch remove 4 x Screws along the outer edge
and 1 x Scr vet located on the ns de of the wheel
arch.
Repeat for other s de.
6. Under veh cle, remove the mudflap and
underbody tr m secured w th 3 x scr vets.
7. Remove rubber plug from the chass s ra l.
Repeat for other s de.
8. Remove 2 x bolts secur ng the mpact beam to the
rear panel, access ble from under the veh cle.
Repeat for other s de.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 6 Issue Date: 03-05-19
9. Peel away bumper from the ends and remove from
veh cle along w th the mpact beam. Ensure to
d sconnect any electr cal connectors.
10. Feed 1x Nut plate on w re and 1 x Nutplate nto the
chass s ra l.
Loosely secure the s de arm assembly to the s de of
the chass s ra l w th 2 x M12 bolts complete w th 1 x
washer per bolt, and to the unders de w th 1 x M12
bolt complete w th 1 x washer.
Repeat for other s de.
11. L ft cross tube to the s de arms and loosely secure
each s de w th 3 x M12 bolts complete w th 2 x
washers and 1 x nut per bolt.
Pos t on the towbar and torque all bolts.
M12 : 125Nm.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 7 Issue Date: 03-05-19
12. Remove 3 x Scr vets secur ng mpact beam bumper
tabs to bumper.
13. Remove 2 x cl ps secur ng top of mpact beam to
bumper.
14. Where appl cable, release smart key antenna from
mpact beam.
15. Detach w r ng from mpact beam, then remove
and d scard mpact beam from rear bumper.
16. On outer surface of the bumper determ ne the centre
and mark off 90mm w de and 125mm long measured
from the bottom edge of the bumper.
Cut out the marked off area and deburr edges.
17. On the underpanel tr m (removed n step 6), mark off
and cut out a sect on 200mm from the top edge x
150mm from the s de.
Repeat for the other s de.
90mm
125mm
150
m
200
m

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 8 Issue Date: 03-05-19
18. Where requ red, f t the smart key antenna brackets
to the crosstube w th 2 x Tek screws and secure the
sensor to the mount ng plates w th 2 x M5 bolts
complete w th 2 x washes and 1 x nut per bolt.
IMPORTANT
Due to possible vehicle variations, always confirm
any noted vehicle colour wires with a multi-meter to
ensure the correct function is identified before
soldering or scotch loc ing. For vehicle wires denoted
with two colours (example; RED/GREEN) the first
colour will always be the main wire colour while the
second colour is the thinner trace colour on the wire.
19. At the veh cle LHS rear quarter, remove the vent (1),
grommet underneath the vent (2) and the LHS rear
quarter unders de grommet (3).
20. Dr ll out the two grommet holes (2+3) to Ø30mm.
Ensure the area being drilled into is clear of all
obstructions before drilling.
File down any rough edges and apply rust inhibitor
(not supplied) after drilling.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 9 Issue Date: 03-05-19
21. From ns de of the vent cav ty, route the tra ler patch
(P/No: 101469-WL) (1) out through the grommet (2)
located under the vent. Note: TheECU connector,
ground ring terminal and tail harness connector
stay inside the vent cavity. Refer to the trailer patch
harness grommet orientation.
22. Ins de the LHS rear quarter vent cav ty, secure the
tra ler patch ground r ng term nal (1) to the veh cle
ground ng po nt (2).
23. Connect the tra ler patch connector (1) to the ECU
(P/No: 04826) (2). Locate a su table area on the
sheet metal (3) where the ECU w ll be mounted and
clean w th an alcohol w pe (not suppl ed). Remove
the back ng from the back of the ECU and mount the
ECU (2) onto the sheet metal area (3). Ensure the
ECU is mounted with the connector pointing
downwards.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 10 Issue Date: 03-05-19
24. Connect the tra ler patch connectors (1) n between
the veh cle LHS 4-way connectors (2).
25. Connect the tra ler patch 12-way connector (3) to
the veh cle harness mat ng 12-way connector (4).
26. At the rear exter or of the veh cle, leave enough
length on the ta l harness so the plug can be
mounted later.
27. Route the ta l harness (ta l length: 1200mm) (2)
across the LHS and up nto the dr lled out hole (3).
Adjust the tra ler patch harness grommet so that t s
seated correctly and cable t e (not suppl ed) n place.
28. Connect the ta l harness 8-way connector (1) to the
tra ler patch mat ng 8-way connector (2).
29. Waterproof the connectors by apply ng electr cal
grease or s l cone (3) to the back of each connector.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 11 Issue Date: 03-05-19
30. In the eng ne bay, route the power harness (P/No:
04825) (1) from the battery area and down the
eng ne bay to the unders de of the veh cle. Do not
connect the power harness ring terminal to the
battery at this point.
31. Route the power harness (1) along the LHS chass s
ra l towards the LHS rear quarter of the veh cle.
Connect the power harness 1-way connector to the
tra ler patch 1-way mat ng connector. Keep harness
routing clear of all sharp objects, moving parts or
areas of extreme heat. Secure the harness with
cable ties (not supplied) after routing.
32. In the eng ne bay, secure the power harness r ng
term nal (1) to the battery pos t ve term nal (2).
33. The RPA can be d sabled v a a sw tch (1) on the
centre console.
34. Test the tra ler patch funct on us ng a l ght board or
mult -meter.
35. Secure all harnesses us ng cable t es (not suppl ed).

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER 03257RW
KIA SPORTAGE QL MY19 CL4
49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
Rev: A Page 12 Issue Date: 03-05-19
36. Ref t rear bumper by follow ng steps 1 to 6 and 9
n reverse order.
37. Where appl cable, secure smart key antenna to
smart key antenna brackets.
38. Secure loose w r ng to towbar us ng cable t es.
39. Secure the 2 x bumper tabs to the bumper w th 2 x
scr vets and secure, n pos t on to the crosstube,
w th 2 x tek screws.
40. Place the f tt ng nstruct ons n the glove box after
f tment.
41. Determ ne an appropr ate pos t on for the plug
bracket. Mark out and dr ll 2x ø5mm holes 69mm
apart on bumper sk n to support plug bracket.

49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: A Page 13 Issue Date: 03-05-19
THANK YOU FOR PURCHASING HAYMAN REESE.
WITH CORRECT MAINTENANCE AND CARE THIS PRODUCT WILL PROVIDE A
LIFETIME OF TROUBLE-FREE OPERATION.
TOWBAR MAINTENANCE AND CARE:
1.
Hayman Reese recommend that the towbar LUG or TBM (tow ball Mount) Pull P n and R
-
cl p are removed
and stored when not n use. Removal of LUG or TBM (tow ball mount) s adv sable when not n use to
ass st w th any of the follow ng.
•Ensure rear number plate s not obscured.
•Allow max mum ava lable departure angle and prevent any potent al nterference.
•Prevent poss ble nterference w th veh cles reverse sensors or camera detect ng a tow ball mount
as an obstruct on dur ng revers ng.
•Removes towball mount as an obstruct on for when mov ng around the rear of the veh cle.
2.
Hayman Reese recomme
nds rout ne nspect on of your towbar to ensure trouble free tow ng.
•Bolt secur ty and tens on should be regularly nspected and checked for correct tens on. Replace
any worn or defect ve parts w th su table grade & class fasteners. Inspect on should be requested
to co nc de w th veh cle major serv ces.
3.
It s the owner’s respons b l ty to ensure tow ng and down ball we ght capac t es of the tow ng veh cle are
not exceeded.
•Tow ng and down ball we ghts allowable may d ffer accord ng to model var at ons. Please refer to
owner’s manual or veh cle dealer to conf rm exact rat ng for your veh cle model var ant.
•It s not uncommon for the veh cle tow rat ng to d ffer from the towbar rat ng. When th s occurs,
the lesser rat ng must be adhered to.
•For veh cles f tted w th enhanced veh cle funct ons that may be altered/changed when tow ng .e
Tra ler sway m t gat on, bl nd spot detect on, adapt ve cru se control etc. Please consult owner’s
manual to understand changes enabled when tow ng and after tow ng.
WARRANTY INFORMATION:
Hayman Reese Towbars are covered by a L fet me Warranty.
Our goods come w th guarantees that cannot be excluded under the Austral an Consumer Law. You are
ent tled to a replacement or refund for a major fa lure and for compensat on for any other reasonably
foreseeable loss or damage. You are also ent tled to have the goods repa red or replaced f the goods fa l to
be of acceptable qual ty and the fa lure does not amount to a major fa lure.
For further deta ls please v s t www.haymanreese.com.au/warranty or contact customer serv ce on
1800 812 017 or [e-mail].

49
-
75 Pac f c Dr ve Keysborough, VIC 3173
Phone: [phone]
Ema l: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: A Page 14 Issue Date: 03-05-19
HAYMAN REESE SMART
PIN
Your Hayman Reese towbar s equ pped w th Smart P n technology to help reduce towbar tongue rattle n most
dr v ng cond t ons. Please ensure below nstruct ons are understood and rout ne ma ntenance s carr ed out to
ensure best tow ng exper ence.
Regularly nspect for wear and check the t ghtness of the Smart P n Nut. Follow nstruct ons below to re
-
t ghten the nut as necessary when movement and no se n the tow ball mount s noted.
•Before tow ng, ensure R-Cl p s properly nstalled and Smart p n nut s nstalled and tens oned.
Replacement parts are ava lable from your Hayman Reese D str butor.
TOWBALL MOUNT REMOVAL/INSTALLATION
STEP 1
Insert Tra ler Ball Mount (TBM) (a) nto towbar
h tchbox (b), al gn ng hole n TBM shank (c) w th
hole n h tchbox (d) (F g. 1)
STEP 2
Insert Smart P n (e) through hole n h tchbox and
hole n TBM shank (g); ensure the locators are
nserted nto the notches n the h tchbox (F g. 2)
STEP 3
Screw Smart P n Nut (f) onto Smart P n (g); t ghten
Smart P n Nut unt l f nger t ght, ensur ng TBM s
restra ned from up and down movement.
STEP 4
T ghten Smart P n Nut by turn ng nut a further
1/8th of a turn n the clockw se d rect on us ng a
24mm spanner (F g. 4).
STEP 5
Install Smart P n R-Cl p through the hole that
prov des best clearance or eas est access. (F g. 5)
Fig. 1
Fig. 4
(d)
HITCHBOX
(b)
Fig. 5
TRAILER BALL
MOUNT
(a)
(c)
Fig. 3
SMART PIN NUT
(f)
SMART PIN
(e)
Fig. 2
R
-
CLIP
(g)