Hayman Reese 03291RW User manual

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 1Issue Date: 24-05-19
PRODUCT DETAILS:
Part Number:
03291RW
Maximum Towing Braked:
2000
kg
ECU Number:
Maximum Towing Unbraked:
750
kg
Tail Harness Length Required:
1800 mm
Maximum Static Ball Load:
150
kg
TBM/Lug Part Number:
21126
Wiring Part Number:
100182-WL
FITTING DETAILS:
Towbar Installation Time:
80 Mins.
Vehicle Coding Required:
NO
Wiring Installation Time:
20 Mins.
RPA Disable/Other:
NO
Total Installation Time:
100 Mins.
Bumper Cut Required:
Yes

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 2Issue Date: 24-05-19
ENSURE THAT INSTRUCTIONS ARE UNDERSTOOD PRIOR TO FITMENT.
BEFORE YOU START:
1. Hayman Reese recommends that instructions are read completely prior to fitment.
2. Check all hardware items have been included refer to assembly diagram.
3. Please ensure this towbar is only fitted to vehicle models as per Hayman Reese application guide
(www.haymanreese.com.au).
4. Bumper Cuts
5. Vehicle and bumper variations can and do occur during vehicle manufacture after initial towbar
design. Fitment of towbar to vehicle and accuracy of bumper cut must be assessed prior to any
bumper modifications made. Incorrect bumper cuts are not covered under Hayman Reese warranty.
6. NOTE: Bumper cuts need to be approached with care, refer to notes below.
Bumper centreline –where the centreline of the bumper needs to be determined, the installer
must assess centre point by measurement of bumper width or determining two symmetrical
reference points to give centreline.
Bumper edge –To assist with accurate bumper cut measurement, reference to the start of the
bumper edge is now being commonly used.
oMeasure from bottom edge along bumper and around corner to the 70 mm point
(Figure 1).
oDo not measure from visible bumper front of corner, upwards (Figure 2).
7. Drilling
For any required drilling during installation, ensure that the area is clear of fuel, electrical & other components that may be
damaged.
All holes drilled into the body panels shall have all burrs & swarf removed then coated with a suitable rust preventative paint.
8. Bolts/Fasteners
Ensure that all hardware is fastened to correct torque as specified in this fitting instruction.
All fasteners supplied with this product are used to achieve a specified clamp loading. If replacement is required ensure that
fasteners of the same grade and class are used.
9.
10. 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.
11.
12. Product Labels
a. Towbar load rating sticker provided with this product shall be conspicuously located on inside rear end of the driver’s door.
b. Powertrain Control Module (PCM)/Body Control Module (BCM) upgrade warning label will be provided in towbar kit for
vehicles as required. Affix warning label in door and owner’s handbook.
WARNING:
1.
2. Do not, drill, cut, weld or otherwise modify the towbar.
3. 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.
Figure 1
INCORRECT
CORRECT
Place Vehicle PCM/ BCM upgrade
warning label in door AND on front
cover of owner’s service handbook
Place Load Rating
sticker inside driver’s
door here
Figure 2

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 3Issue Date: 24-05-19
TOWBAR ASSEMBLY DIAGRAM
ITEM
DESCRIPTION
QTY
ITEM
DESCRIPTION
QTY
1
HYUNDAI ILOAD WELDED ASSY
1
13
WASHER PLAIN 1/2X1-1/8X16G
10
2
SIDE ARM ASSY RH
1
14
M12x1.75 HEX NUT PC8
4
3
SIDE ARM ASSY LH
1
15
TRAILER BALL MOUNT
1
4
ANTI-RATTLE PULL PIN ASSY GOLD
1
16
PLUG BRACKET
1
5
HEX NUT M10x1.5
4
17
NUT NYLON LOCK HEX HD M4X0.7P G8
2
6
SPACER Ø12.7 x 1.2 x 90
2
18
TOWBALL 50MM FLAT CHROME 3500KG HR
1
7
CS M10 x 130 Bolt
4
19
HAYMAN REESE LOGO STICKER
1
8
WASHER FLAT M10 X 23 X 2 Z/P
12
20
"D" SHACKLE 10mm
2
9
SPACER Ø12.7 x 1.2 x 84
2
21
HITCH BOX COLLAR COVER
1
10
LOOSE PLATE 32x32x6 11mm HOLE
6
22
ACRYLIC COMPLIANCE LABEL
1
11
SET SCREW HEX HD M10x35x1.25P
4
23
WIRING LOOM
1
12
M12x1.75x45 HEX BOLT PC10.9
6

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 4Issue Date: 24-05-19
1. Remove 2x Plastic trim buttons from top of Bumper on
either side and then remove 4 x Screws from each side.
2. Remove 1x Screw from each side of the Mud Flap.
3. Remove 2x Scrivets below the Bumper Bar on both sides
near the Mud flaps.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 5Issue Date: 24-05-19
4. Remove 1x Bolt from inside the Wheel arch from each
side.
5. Remove 3x Scrivets from the bottom of the Bumper Bar.
6. Remove 2x Bolts from each side which holds the Impact
Beam.

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 6Issue Date: 24-05-19
7. Remove 3x Screws from the inside of the Bumper Bar.
8. Flex Bumper out at the sides then pull inwards, to
remove bumper. Some force may be required.
CAUTION Two person lift required.
9. Remove 2x Scrivets to separate the Impact Beam from
the Bumper Bar and then discard the Impact Beam.
Store Bumper for later fitment.
10. Using a grinder or similar tool, remove the driver side
towing hook.
Cut off here

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 7Issue Date: 24-05-19
11. To fit the LH Side arm.
Insert crush tubes into the side chassis rail mounting
points if they do not have them. The 90mm crush tube
to be inserted into the mount point closest to the
bumper and the 84mm into the other one.
Position the side arm to the outside of the chassis rail
and loosely secure the bottom mounts with 2 x M10
bolts complete with 1 x washer per bolt.
Loosely secure the side mount positions with 2 x M10
bolts complete with 2 x washers and 1 x nut per bolt.
Ensure that 1 x spacer plate is positioned between the
side arm and outside of chassis rail.
12. To fit the RH Side arm.
Insert crush tubes into the side chassis rail mounting
points if they do not have them. The 90mm crush tube
to be inserted into the mount point closest to the
bumper and the 84mm into the other one.
Position the side arm to the inside of the chassis rail and
loosely secure the bottom mounts with 2 x M10 bolts
complete with 1 x washer per bolt.
Loosely secure the side mount positions with 2 x M10
bolts complete with 2 x washers and 1 x nut per bolt.
Ensure that 2 x spacer plates are positioned between the
side arm and inside face of chassis rail.
13. Lift crosstube to the side arms and loosely secure each
side with 2 x M12 bolts complete with 2 x washers and 1
x nut per bolt and 1 x M12 bolt complete with 1 x washer
to the internal weld nut.
Position the bar and torque all the fasteners as specified.
M10 x 1.25 GR 8.8 : 48Nm
M12 x 1.75 GR 10.9 : 109Nm

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 8Issue Date: 24-05-19
14. Place masking tape on the outside areas of Bumper
bar skin so not to damage the surface while cutting.
Establish Centre line of Bumper Bar Skin then
measure, mark, and cut out as shown in diagram
using an appropriate tool.
Ensure that cut is clean of swarf and rough edges.
15. Determine an appropriate position for the plug bracket.
Mark out and drill 2x ø5mm holes 69mm apart on
bumper skin to support plug bracket.
10 mm
94 mm

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 9Issue Date: 24-05-19
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 locking. 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.
16. Remove the LHS and RHS tail light assemblies
(1)
17. On the rear RHS underneath bumper, route
the Trailer Patch Harness (P/No: 100182-WL)
(1) up the RHS tail light cavity.
Connect the RHS Trailer Patch Harness (1) to
the vehicle harness tail light connector (2).
Route the Trailer Patch Harness towards the
LHS tail light cavity along the towbar.
Connect the LHS Trailer Patch Harness (1) to
the vehicle harness tail light connector (2).

TOWBAR
INSTALLATION INSTRUCTIONS
PART NUMBER
03291RW
HYUNDAI iLOAD TQ CAD CL4
49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
Rev: APage 10 Issue Date: 24-05-19
18. On the Tail Harness (Tail length: 1800mm) (1)
and mating connector, apply electrical grease
or silicon (3) on to the back of the connectors
(1)(2) to make them water proof.
Connect the Tail Harness (1) to the Trailer
Patch Harness (2).
19. Connect the Trailer Patch Harness (1) to the
tail light assemblies (2) and refit the tail lights
(3).
From outside of the vehicle, secure the tail
harness socket (4) onto the towbar mounting
bracket using M4 fasteners.
Important: Keep harnesses clear of exhaust
when routing.
20. Test trailer harness function using trailer light
board or multimeter.
Secure all harnesses to the vehicle using cable
ties.
Refit the rear bumper in reverse order.
Refit all removed parts and secure all
fasteners ensuring there are no squeaks or
rattles.
Please place the fitting instructions in the
glove box after installation.

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 11 Issue Date: 24-05-19
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 Pin and R-clip are removed
and stored when not in use. Removal of LUG or TBM (tow ball mount) is advisable when not in use to
assist with any of the following.
Ensure rear number plate is not obscured.
Allow maximum available departure angle and prevent any potential interference.
Prevent possible interference with vehicles reverse sensors or camera detecting a tow ball mount
as an obstruction during reversing.
Removes towball mount as an obstruction for when moving around the rear of the vehicle.
2.
Hayman Reese recommends routine inspection of your towbar to ensure trouble free towing.
Bolt security and tension should be regularly inspected and checked for correct tension. Replace
any worn or defective parts with suitable grade & class fasteners. Inspection should be requested
to coincide with vehicle major services.
3.
It is the owner’s responsibility to ensure towing and down ball weight capacities of the towing vehicle are
not exceeded.
Towing and down ball weights allowable may differ according to model variations. Please refer to
owner’s manual or vehicle dealer to confirm exact rating for your vehicle model variant.
It is not uncommon for the vehicle tow rating to differ from the towbar rating. When this occurs,
the lesser rating must be adhered to.
For vehicles fitted with enhanced vehicle functions that may be altered/changed when towing i.e
Trailer sway mitigation, blind spot detection, adaptive cruise control etc. Please consult owner’s
manual to understand changes enabled when towing and after towing.
WARRANTY INFORMATION:
Hayman Reese Towbars are covered by a Lifetime Warranty.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are
entitled to a replacement or refund for a major failure and for compensation for any other reasonably
foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to
be of acceptable quality and the failure does not amount to a major failure.
For further details please visit www.haymanreese.com.au/warranty or contact customer service on
1800 812 017 or [e-mail].

49-75 Pacific Drive Keysborough, VIC 3173
Phone: [phone]
Email: [e-mail]
CUSTOMER INFORMATION
PLACE THESE INSTRUCTIONS IN THE
VEHICLE’S GLOVEBOX AFTER INSTALLATION
Rev: APage 12 Issue Date: 24-05-19
HAYMAN REESE SMART PIN
Your Hayman Reese towbar is equipped with Smart Pin technology to help reduce towbar tongue rattle in most
driving conditions. Please ensure below instructions are understood and routine maintenance is carried out to
ensure best towing experience.
Regularly inspect for wear and check the tightness of the Smart Pin Nut. Follow instructions below to re-
tighten the nut as necessary when movement and noise in the tow ball mount is noted.
Before towing, ensure R-Clip is properly installed and Smart pin nut is installed and tensioned.
Replacement parts are available from your Hayman Reese Distributor.
TOWBALL MOUNT REMOVAL/INSTALLATION
STEP 1
Insert Trailer Ball Mount (TBM) (a) into towbar
hitchbox (b), aligning hole in TBM shank (c) with
hole in hitchbox (d) (Fig. 1)
STEP 2
Insert Smart Pin (e) through hole in hitchbox and
hole in TBM shank (g); ensure the locators are
inserted into the notches in the hitchbox (Fig. 2)
STEP 3
Screw Smart Pin Nut (f) onto Smart Pin (g); tighten
Smart Pin Nut until finger tight, ensuring TBM is
restrained from up and down movement.
STEP 4
Tighten Smart Pin Nut by turning nut a further
1/8th of a turn in the clockwise direction using a
24mm spanner (Fig. 4).
STEP 5
Install Smart Pin R-Clip through the hole that
provides best clearance or easiest access. (Fig. 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)