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M3 Hard Core Installation Instructions

 

HARDWARE KIT:

  • 2) 5/16" X 1-1/4" bolts
  • 10) 3/8" X 1-1/4" bolts
  • 10) 3/8" self locking flange nuts
  • 2) 5/16" self locking flange nuts
  • 10) 3/8" flat washers
  • 2) 5/16" flat washers
  • 8) #10 sheet metal screws (not needed w/ harness bar)
  • 2) 1/4" bolts w/ nuts and flat washers if harness bar equipped
  • 2) rear back-up plates

 

TOOLS NEEDED:

  • safety glasses
  • wrenches
    • 2) 7/16" (if harness bar equipped)
    • 2) 1/2"
    • 2) 9/16"
    • 10mm
    • 12mm
  • #2 phillips head screwdriver
  • drill w/ 3/8" & 1/8" drill bits (1/8" bit not needed w/ harness bar)
  • belt sander, die grinder or saw for cutting plastic interior panels

 

 

This is a work in  progress. Check back later for the finished instructions

1) Unsnap and remove front hoop covers then remove the phillips head screws holding the rear hoop covers.

2) Pull the center to release and remove the reusable plastic rivet fasteners that hold the shoulder harness guide covers. Pull forward on the front and straight up on the top to release. Slide the belt out through the provided slot and remove the cover.

3) Pull up on the door seal protectors, unsnap and remove.

4) There are some more of the plastic rivets holding the quarter trim on either side behind the seats. Remove the fasteners to free the panel.

5) Pull down on the top release handle and remove it. Pull up on the windblocker and remove it also. This one is tight and can be a little stubborn.

6) Pull up on the panel at the rear of the console. This one can be difficult also, pull vertically with a slight twist to get it loose. Be careful the clips are tight and easy to break.

7) Remove the fasteners from the large plastic bulkhead behind the seats, separate the front from the rear at the top, rotate forward, push back just behind the console to allow the tab that slides under the console to clear and remove from car.

8) If you have speakers, unplug and remove them together with the bracket by removing the 3 nuts w/ 10mm hex heads.

9) Remove the top latch from the cross brace by removing the 2 bolts w/ 10mm hex heads.

10) Loosen the wiring harness clips and seat belt guides. Unbolt and remove the cross brace and hoops with the rear plastic trim still attached. Unsnap the plastic cover and remove the fasteners with a door panel tool, screwdriver or claw hammer.

11) .

These bolts will not be needed to install the roll bar.

12) Remove the fasteners that hold the side and rear plastic interior panels remove the upper and lower side panels and the large center panel.

13) Install the main hoop reinforcement plates by creating an opening in the wheel well using a jig saw with a fine tooth metal cutting blade, or some other tool appropriate for light sheet metal cutting. Drill 3/8" holes through the roll bar mounting plates into the channel. Insert the reinforcment plates with the prewelded nuts and bolt them in place to 33 ft/lbs. The sandwiching of this double walled panel adds considerably to the strength of the main hoop mounting. Once the plates are installed bend the flaps back into place and seal the crack with expanding foam. Once the foam dries, trim any excess and spray the area with undercoating. This proceedure in no way compromises the structural integrity of the vehicle.

 

WARNING: This article is sold without warranty, expressed or implied. No warranty is made to this product's ability to protect the user from any injury or death. The user assumes that risk.

Updated Feb 8, 2020