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M1/M2 Hard Core Installation Instructions
1) Put the top down
2) REMOVE THE TRIM PANELS COVERING THE SEAT BELT TOWERS. (THESE
PIECES ARE CALLED QUARTER TRIM BY MAZDA.)
Remove the weather-stripping that runs along the front edge of the trim panel at the rear of the door opening. (you might find it necessary to loosen the 4 Phillips head screws in the scuff plate that runs along the bottom of the door sill on some early models)
Remove the plastic cover from the shoulder harness guide (it just snaps off), loosen the bolts and remove the bolt and spacers from the guide.
On the '94-'97 models Remove the cockpit brace end covers (they also snap), loosen the bolts and remove the cockpit brace.
There is a small plastic clip at the rear of the trim panel just behind the hole the shoulder harness guide bolt goes through. Remove the clip by pulling it toward the rear of the car.
Remove the rectangular seat belt trim ring at the front of the panel and the 2 fasteners in each trim panel located on the inside just above the package tray, one is a kind of plastic rivet that is loosened by lifting the center portion and pulling it free, the other is another one of the boot cover snaps with the 10mm head. If you have an NB with the wind blocker remove the screws and lift the wind blocker out. The trim panel can now be removed by pulling it toward the center of the car, there's a couple of snap type fasteners down low just behind the door that you will need to pop loose as the panel is pulled free.
3) PUT THE TOP UP - Loosen the carpet from the front of
the package shelf behind the seats and fold it back.. A claw hammer is a good tool for removing the plastic
carpet fasteners. Lower the top. (Pre '99 leave the window zipped in,
be careful not to crease the window ) Some sort of cover for the window
is not a bad idea. Remove the large silver metal panel that
makes up the front part of the package shelf by removing the several bolts
w/ 10mm heads that hold it in place and releasing any wire loom fasteners.
Lift the cover up and out of the car. Remove the insulation pads on
either side of the fuel tank cover.
If the car has antilock brakes you will need to relocate the ABS sensor wiring harnesses. Jack up the rear of the car and support with sturdy jack stands. Remove the wheels and the plastic inner splash panels. The harnesses run from the sensors, mounted next to the brake rotors, up through rubber bulkhead plugs in the areas just to either side of the fuel tank. Trace the harnesses forward to the connectors just behind the seats, on either side of the area just uncovered by removal of the fuel tank cover / package shelf. Unplug the connectors, untangle the harnesses from the wire holders and other wiring, push the bulkhead plugs through and pull the wires through into the wheel wells. After the roll bar is bolted in, using a 3/4" holesaw, being careful not to drill into any wiring or hoses, open a hole to clear the roll bar plate. Reroute the wiring and reinstall the bulkhead plugs.
4) REMOVE THE LOWER SEAT BELT REEL BOLTS (16mm pre'94 - 17mm '94 and later) AND SPACERS.
5) Make certain the area where the rear mounting plates attach is clear of all body caulk and weld spatter allowing the rear plates to sit flat down on the panel.
6) SET THE BAR IN THE CAR - BE CAREFUL The rear brace foot plates will just fit under the front edge of the package tray, work the rear braces past the several wiring harnesses and battery cables in this area being careful not to damage any of the wiring. Also watch the front mounting plates, they will be very close to the seat backs at this point. The lower mounting points align with the lower seat belt reel bolt holes. The roll bar plates fit against the seat belt reels which stay in their original location but do NOT use the original spacers.(FIG# HC2) Once the bar and the seat belt reels are in position, snug but do not completely tighten the seat belt reel mounting plates using bolts from the hardware kit and small OD flat washers from the stock bolts. Make sure that your seat belts are on the inside of the roll bar. On some cars the captive nut for the belt reel bolt will not be exactly vertical and will make threading the bolt difficult or impossible with the bar installed. Use a large Phillips screwdriver or tapered bar working through the roll bar mounting slot to align the nut.
7) JACK UP THE REAR OF THE CAR AND SUPPORT WITH STURDY JACK STANDS - Remove the wheels and plastic splash panels from the front of the inner fenders. (pre 99 - 4 bolts w/ 10mm heads / NB - 4 plastic fasteners w/ Phillips heads)
8) GET THE DRILL AND SAFETY GLASSES - Install the rear
plates and tighten the rear of the bar FIRST.
9) Trim the package shelf panel as needed and reinstall.
10) CUT QUARTER TRIM PANELS - In order to reinstall the trim
panels, cut a notch to clear the main hoop foot plate, (see
Image 1). We use a small air powered reciprocating saw with a fine
tooth blade. A jigsaw, hack saw or a coarse half-round file will do. It's
fairly evident as to where the cut needs to be made, just cut the panel
and trim to fit. Slide the panel in behind the bar to install. It helps if
the panel is warm. Take several small cuts to get a good fit.
11) REINSTALL THE REMAINING PARTS - The NB windblocker isn't compatible as is but some have relocated it forward to clear by drilling a new set of holes and attaching with sheet metal screws.
January 24, 2018 10:50 AM