Installation Instructions for Saturn Aura and Chevrolet Malibu

Part Numbers:

• 36479
• 90194
• 06658
• 36327 (U-Haul)

Wiring Access Location:

• PC1, PC2

Tools Required:

• Wrenches: 11/16", 3/4"
• Drill Bits: 1/2", 3/8"
• Pull Wires (Provided)

Step-by-Step Instructions:

For Vehicles Without Existing Holes:

1. Position Hitch:

   • Raise the hitch into position and align it over the bumper attachment bolt.
   • Ensure the bracket sits flat against the frame rail.

2. Drill Holes:

   • Mark and center punch the hole locations using the hitch as a template.
   • Drill two 3/8" holes through the end panel. Remove burrs.

3. Install Hardware:

   • Tape spacers into position behind the end panel.
   • Feed pull wires through the spacers and attach carriage bolts.
   • Pull reinforcement plates and carriage bolts into position.

4. Secure Hitch:

   • Install conical washers and nuts onto the carriage bolts.
   • Tighten all fasteners according to torque specifications.

For Vehicles With Existing Holes:

1. Prepare Hardware:

   • Tape spacers into position.
   • Feed pull wires through the spacers, attach carriage bolts, and pull into place.

2. Install Hitch:

   • Raise the hitch into position.
   • Secure with conical washers and nuts.

3. Drill Frame Holes:

   • Drill two 1/2" holes through the frame rail using the hitch as a guide.

4. Install Frame Hardware:

   • Feed pull wires through the hitch bracket and frame rail.
   • Attach spacers and carriage bolts to the pull wires and pull into position.
   • Secure with lock washers and nuts.

5. Torque Fasteners:

   • Tighten all 3/8"-16 GR5 fasteners to 30 ft-lbs (47 N*m).
   • Tighten all 1/2"-13 GR5 fasteners to 75 ft-lbs (102 N*m).

Hardware List:

• (2) Carriage Bolt 3/8"-16 x 1.50" GR5
• (2) Carriage Bolt 1/2"-13 x 1.75" GR5
• (2) Spacer 1/4" x 1" x 2" (Square Hole)
• (2) Spacer 1/4" x 1" x 3" (Square Hole)
• (2) Conical Washer 3/8"
• (2) Conical Washer 1/2"
• (2) Lock Washer 1/2"
• (2) Nut 3/8"-16
• (2) Nut 1/2"-13

Safety Notes:

• Regularly check the hitch to ensure all fasteners and the ball are securely tightened.
• If the hitch is removed, plug all holes in the trunk pan or body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Observe safety precautions when working beneath the vehicle and wear eye protection.
• Do not cut access or attachment holes with a torch.

Specifications:

• Weight Carrying Capacity: 3,500 lbs (1,589 kg) trailer weight, 300 lbs (136 kg) tongue weight.
• Weight Distributing Capacity: Not applicable.
• Drawbar must be used in the rise position only.
• Product complies with V.E.S.C. Regulation V-5 and SAE J684.

Additional Notes:

• Installation time for professional installers is approximately 30 minutes.
• For more detailed instructions, refer to the QR code or manual provided.

Installation Instructions for T-Connector Adapter

Part Numbers:

• 118423

Tools Required:

• Phillips Head Screwdriver
• Drill (3/32” Drill Bit)
• Trim Panel Remover

Step-by-Step Instructions:

1. Open the Trunk:

   • Open the trunk and temporarily disconnect the driver’s side taillight housing by unscrewing the three wing nuts holding it in place.

2. Route the T-Connector:

   • Route the T-Connector with the yellow wire up from underneath the vehicle through the opening between the bumper and body panel.

3. Connect the Driver-Side T-Connector:

   • Separate the vehicle’s taillight connectors and insert the T-Connector in between the separated connectors.
   • Ensure the mating surfaces of the vehicle wiring connectors match the T-Connector ends.
   • Verify all connector surfaces are clean and free of dirt.
   • Be careful not to damage the locking tabs and ensure connectors are fully inserted with locking tabs in place.

4. Passenger-Side Installation:

   • Repeat steps 1 through 3 on the passenger’s side using the T-Connector end with the green wire.

5. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle’s frame or cross member.
   • Avoid drilling into the vehicle floor or bed.
   • Clean dirt and rustproofing from the area. Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution:

   • Verify what is behind the surface before drilling to avoid vehicle damage or personal injury. Do not drill into any exposed surfaces.

6. Route the 4-Flat Connector:

   • Route the T-Connector harness 4-flat end to the center of the vehicle.
   • Secure the wire and converter to the vehicle crossmember or other mounting points using the provided tie straps.

7. Reconnect the Vehicle’s Taillights:

   • Reinstall the vehicle’s taillight housings, ensuring all connections are secure.

8. Test the Installation:

   • Test and verify the installation with a test light or trailer to ensure functionality.

   Specifications:

   • Max. stop/turn light: 1 per side (2.1 amps)
   • Max. tail lights: (4.2 amps)

Safety Notes:

• All connections must be complete for the T-Connector to function properly.
• Overloading circuits can cause fires. Do not exceed the lower of the towing manufacturer’s rating or the unit specifications.

Manufacturer Notes:

• Mount the 4-flat end in an accessible location with a bracket or electrical box (not included).
• Refer to the vehicle owner’s manual and instruction sheet for additional information.