Demco TP20080 User Manual
BOLT TORQUE SPECIFICATIONS
STANDARD BOLTS:
Size Grade Torque
5/16” 5 20 ft/lbs.
3/8” 5 35 ft/lbs.
7/16” 5 56 ft/lbs.
1/2” 5 85 ft/lbs.
Grand Vitara: Centers-23” Pin Height-16-3/4”
XL7: Centers-23” Pin Height-18-3/4”
METRIC BOLTS:
Size Torque
8mm 22 ft/lbs.
10mm 42 ft/lbs.
12mm 70 ft/lbs.
14mm 95 ft/lbs.
13
7-08
TP20080,Rev.5
Suzuki Grand Vitara &
Grand Vitara XL..7
4
2
5
6
16
19
1
20
7
8
12
14
15
6
5
4
11
10
3
20
9518080 PARTS LIST
REF. PART
NO. NO. QTY. DESCRIPTION
9
17
9
18
1. 09812-35 1 Right Frame Mount
2. 09813-35 1 Left Frame Mount
3. 13136-35 1 Crossmember
4. 09815-35 2 Z Bracket
5. 09816-95 2 Frame Bushing
6. 05104 2 7/16”-14 UNC x 3” Hex Bolt Gr.5
7. 00078 2 7/16” Lockwasher
8. 00079 2 7/16”-14 UNC Hex Nut
9. 01254 4 1/2”-13 UNC x 1-1/2” Hex Bolt Gr.5
10. 00084 4 1/2”Lockwasher
11. 00083 4 1/2” -13 UNC Hex Nut
12. 09795 2 10mm x 1.25 Punch Lock Nut
13. 07479 2 8mm x 1.25 x 25mm Hex Bolt
14. 07286 2 8mm Lockwasher
15. 09228 2 8mm Fender Washer
16. 00523 2 3/8”-16 UNC x 1-1/4” Hex Bolt Gr.5
17. 00060 2 3/8” Lockwasher
18. 00061 2 3/8”-16 UNC Hex Nut
19. 00059 2 3/8” Flatwasher
20. 07594 6 3/8” Self-Threading Bolts
21. 09817-35 2 Crossmember Shims (not shown)
22. 12329 1 Loctite(not shown)
Please order replacement parts by PART NO. and DESCRIPTION.
Doing Our Best to Provide You the Best
WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARATION
R
OF THE TOW BAR FROM THE TOWING VEHICLE, SEPARATION OF THE TOWED VEHICLE FROM THE TOW BAR, CAUSING SEVERE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE.
IMPORTANT INSTALLATION ITEMS
CAUTION
Safety is of utmost importance at all times. There are several items that
must be checked each time before using and while using a tow bar.
Before allowing anyone to hook up or operate a tow bar, be sure they
have read and understand the proper operating procedure.
DO NOT use worn or damaged cables and/or pins.
Be sure the SAFETY CABLES are hooked, chassis to chassis, to both
the towing and towed vehicles using the crisscross method.
Check clearance between vehicles in a turning situation.
Check base plate mounting bolts for tightness and frame for metal fa-
tigue.
Do not load the towed vehicle with anything as you may exceed the
towing capacity of the tow bar.
Keep fi ngers away from pivot points to prevent personal injury.
Be sure the steering components of the towed vehicle are properly
aligned.
NOTE: This unit can be backed up in moderate increments. Any se-
vere backwards cornering could result in damage to the Tow Bar and/
or towed vehicle chassis.
For automatic transmissions: Consult your vehicle owners manual
for towing suitability with the drive shaft connected. Otherwise, the
towed vehicle will have to be equipped with a transmission pump or
drive shaft disconnect.
Check to make sure that all lights are in proper working order.
The information on towability of vehicles is reprinted with permission of MotorHome
Demco does not warrant the information to be correct. Always consult
your towed vehicle owner’s manual and follow towing instructions. Each
year, MotorHome© Magazine, compiles a list of vehicles that can be
towed four-down behind a motorhome with no modifi cations required.
This guide contains only those vehicles that have been approved by their
manufacturers for towing. This list is enclosed with this manual.
Caution: MotorHome
towing speed limits slower than 55 m.p.h., or distance limits of less than
200 miles. At a minimum, these vehicles require signifi cant modifi cation, such as the use of an aftermarket product, to make them towable.
The availability of a Demco Tow Bar Base Plate does not imply that
these vehicles can be modifi ed or that there is an aftermarket product
available. Refer to your vehicle owner’s manual or consult your dealer
to determine whether your vehicle can be modifi ed to make it towable.
Failure to observe this precaution could result in property damage or
personal injury.
©
Magazine, and is believed to be reliable. However,
©
Magazine left out any vehicles that have
DEMCO products and accessories are intended to be
installed by professional installers with experience,
proper equipment and the ability to do modifi cation
work. Installers with these qualifi cations can be found
in RV and Automotive Service Centers.
If the car to be towed has been in an accident, the
chassis may be damaged in an area where the Base
Plate attaches. It may no longer be suitable for towing. Extreme caution and careful examination are
required in such a situation. It is also likely, even from
a minor accident, that the hole alignment will be more
diffi cult due to hole alignment problems.
Many DEMCO Base Plates are designed to use existing holes and hardware to mount the Base Plate
to the towed vehicle. Even though the bolt is there,
however, do not assume it is adequate for mounting
the Base Plate. Manufacturers make many changes
in hardware both within and between model years. Be
sure the bolt is long enough to protrude past the nut
a distance no less than 1/2 the diameter of the bolt,
after the Base Plate is mounted. The threads should
be in good condition. We require that “
Blue” be used on all bolts. If a new bolt is required,
be sure it is SAE Grade 5 or Metric 8.8.
NOTE: The dimensional variations between otherwise
identical vehicles can be considerable. Some minor modifi cations may have to be made to ensure
a proper fi t.
INSTALLATION INSTRUCTIONS
1. Remove grill by opening hood and removing plastic
push fasteners from top of grill.
2. Carefully pull grill
straight out by headlight area, and set
aside.
4. Unplug side marker lights, and pull bumper cover off.
3. Remove bumper cover by removing plastic push fasten-
ers from top side, three bolts from bottom side. Remove
one plastic push fastener from inner fender to bumper
cover, and one bolt from inner fender to bottom of front
fender, on each side.
5. Remove one plastic push from inner fender to brace,
which is bolted to frame, on each side. (no picture)
6. From inside of frame out put 7/16” x 3” bolt thru frame
and slip bushing through outside of frame over 7/16”
bolt. Do this on each side.
NOTE: For Grand Vitara XL.7, 7/16” x 3” bolt must be
installed from outside of frame inwards. Do this by fi rst
putting a 4” long solid wire from inside frame. Slide
bushing through large hole with wire inside of it. Put
frame mount up and put 7/16” bolt through mount and
into bushing and bolt will push wire out of the way. Then
install 7/16” lockwasher and 7/16” hex nut. Proceed to
next step
7. Install right and left frame mounts. Put proper side up and push 7/16” bolt through hole
R
and start 7/16” lockwasher, and hex nut. Start 10mm x 1.25 punch lock nut over factory
stud. Push mount up so angle is fl at on front of frame, and clamp with C-clamp. Snug
previously mentioned fasteners. Drill 5/16” holes through frame using mount as a template
(three on each mount).
8. Remove top bumper bolt on each side and install brace with 8mm x 1.25 x 25mm
bolt, 8mm lockwasher, and 8mm fender washer. Secure bottom of brace to frame
mount using 3/8” x 1-1/4” bolt, 3/8” lockwasher,3/8” fl atwasher, and 3/8” hex nut.
We require that “
Blue” be used on all bolts.
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