HMS SportBar and StyleBar
Installation Instructions for the Z3 Roadster
(1998 – 2001 Model Years with Factory Roll Hoops)
PRE-INSTALLATION NOTES
•
This installation booklet was produced to give the installer the information required to install the
HMS SportBar or StyleBar into the 1998 through 2001 Z3 1.9/2.8/2.3/3.0 or M Roadster in cars
equipped with factory Dual Hoops. Note that some 1997 models manufactured after April 1997 may
also use this mounting structure. The instructions in this booklet were complete as of August 2000.
Installation is possible in all Z3 and M Roadster Models through the 2001 model year and may vary
slightly by model and optional stereo equipment. Any change in the vehicles or problems noted by the
installer should be reported directly to the HMS motorsport Customer Service Department at 888467-3269.
•
Carefully read all instructions before proceeding with this installation. It is important to understand
how the various parts are attached before they are removed. This will help you avoid breaking the
factory fasteners during removal of the interior trim. If the instructions are unclear, do not hesitate to
contact our Customer Service Department for assistance.
•
The Installation Kit includes several items of hardware listed in Schedule 1. Please verify that you
have all of the items before you begin the installation process. We have included several pre-labeled
bags for the storage of the various interior screws and plastic trim caps during disassembly. The
reassembly process will be much easier if all screws and other components are placed into the
designated bags and stored with their related parts as instructed. Note various screws from your car
may vary from our instructions. This may be a result of previous work on your car and/or
production variations from year to year.
•
A recommended Tool List is provided in Schedule 2. All tools on the list are required to complete the
job in a timely manner. The installation time is approximately 4 to 5 hours if this is your first
installation. Subsequent installations should take about 4 hours. An assistant will be very helpful.
These times may vary according to the conditions under which they are performed, the tools that are
used, and your experience with similar installations. The installation can be expedited with the use of
a high-speed die grinder and a tool such as a Roto Zip (used to trim the plastic panels).
•
It is strongly recommended that the inside of the plastic rear window be covered during the entire
installation. The window is replaceable, but expensive and can be easily scratched.
•
Words in italic in this installation manual represent specific Z3 trim pieces or hardware.
REMOVAL OF FACTORY ROLLHOOPS
The Factory Roll Hoops are held in by a series of setscrews. Follow these instructions to remove the
factory hoops
1. Remove the Access Panel Covers and Setscrews for the outer post of
the Roll Hoop.
•
•
There is a small clip that holds the access panel in place. Using a small flat
head screwdriver press down in the center and pull out from the top.
Remove the two setscrews using a T-40 torx head wrench.
Place in Bag 1.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 1
2. Remove Rear Center Console Cover and Base Resonator.
•
Lift up firmly on the front center of the Rear Center Console Cover raising
it about 1.5” so that you can fit a long screwdriver under the cover to
release the rear clips.
•
Using a long flat head screwdriver press
back against the center of a three part
plastic clips (about 2” in from either
side). This will release the back part of
the console cover.
•
Remove the four (4) 15mm large washer
screws holding down the sub-woofer.
Place in Bag 1.
•
Lift out sub-woofer being sure to unplug
the power cable under the left front as
you remove the unit.
3. Remove Inside Roll Hoop Setscrews and Roll Hoops.
•
Remove the setscrew from the inside lower section of the each
roll hoop using the T-40 torx wrench. Place in Bag 1.
•
Pull out the roll hoops. If they do not come out easily, tap them
firmly forward and aft with the heel of your palm as you lift up.
REMOVAL OF REAR CONSOLE
To remove the Rear Console parts of the center console near the e-brake must also be removed to allow
access to rear console-retaining screws. Several Console Valet options are available on your Z3 Roadster,
the Cassette Holder with utility tray and the Cup Holder/Storage Unit are the most common.
1. Remove Cassette Holder or Cup Holder/Storage Unit
•
•
•
Remove Cassette Holder by sliding the unit forward and pulling up on
the back end.
Remove the Cup/Phone Console Valet by removing the rubber plug in
the Rear Coin Tray and removing the screw below. Place the plastic
screw and rubber plug in Bag 2.
Lift out the Console Valet starting from back to front.
2. Remove Rear Coin Tray
•
•
•
Move both seats to the full forward position.
Remove the two screws from the sides, at the back end of the Main Center Console. Place the 2 –
20mm screws with 12mm washers in Bag 2.
Remove the Rear Coin Holder by first lifting the back edge of Main
Center Console adjacent to the Rear Coin Holder. Reach below the
console edge with your fingers and pull up on the edge of the plastic
retaining ring (pictured at right). Lift out the Rear Coin Holder and the
retaining ring below.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 2
3. Remove the Rear Center Console
•
Remove Rear Center Console base screws located at the bottom,
front of the Center Console directly below the previously removed
Coin Tray. Place the two (2) 15mm screws with 9mm washers in
Bag 2. We suggest that you use a magnetic screw driver since
these screws can easily fall down and get lost below the console...
be careful.
•
Pop off the left and right Square Cover Panels on top Rear Console
through which the inside portion of the roll hoops passed. Pop up at
front first than at back.
•
Remove the two 25mm long screws with large washers located in
the position shown at the picture to the right. You don not need to remove the plastic piece below
the Square Cover Panel it will come out as part of the assembly of the Rear Center Console.
Place these two screws in Bag 2.
•
Close the soft-top.
•
Remove the three Plastic Trim Caps that cover
the retaining screws along the back edge of the
Rear Console adjacent to the folded plastic
window. Place a small, flat-head screwdriver at
the center of the long edge of the Plastic Trim
Cap. Insert it into the seam and carefully and
slowly push the screwdriver towards center to
pry off the Plastic Trim Caps.
•
Remove the three (3) 15mm screws with large washers and place them with the Plastic Trim
Caps and in Bag 3.
•
Lift out the Rear Console by pulling up the back edge of the base, tilting the console forward and
lifting straight up and out. You will have to lift up on the base of the rear of the Main Center
Console to release the lower front edge of the Rear Center Console.
REMOVAL OF UPPER & LOWER REAR POST TRIM
1. Seat Belt Post Covers
•
Open the soft-top.
•
Using the small flat-head screwdriver, carefully remove the two outside
and one inside Plastic Screw Head Caps from each of the Seat Belt Post
Covers. Once you have started to pry at one location on a cap, stay at
that point or you will destroy the entire cap. Place the screws and caps
in Bag 4. (Note: These caps are difficult to remove without marring. The
damaged caps can be reinstalled with the damaged edge facing down and
generally are not noticeable. If potentially damaged caps will be
unacceptable, you may want to purchase six new caps from your dealer before
beginning the installation.)
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 3
•
Remove the three (3) retaining screws from each of the Seat Belt Post Covers. Place the 6 screws
(13mm screws integrated 9mm washers) in Bag 4. (Note: These are special screws with integrated
washers that hold on the plastic trim caps.)
•
Using a 16mm open wrench unbolt the Outside Seatbelt Mounting Bolt that is attached to the
outside of the base of each seat. (This is necessary to be able to remove the trim pieces entirely.)
•
Remove the Seat Belt Post Covers by pressing in slightly on the
outside base and lifting up the inside edge at the same time. Once
the fastening tabs are clear of the lower section of plastic rotate and
twist the cap towards the headrest. Slide the seat belt that you just
unbolted through the opening in the Seat Belt Post Cover. During
removal of the cover, be very careful of the three fastening tabs
along the base of the cover they are easily damaged. (Note: Never
stand the Seat Belt Post Covers on their fastening tabs, always lay them
on their side or top.)
2. Lower Rear Interior Trim
•
Remove the left and
right Plastic Door Sills.
The sills are fastened
with three Plastic
Retaining Clips.
The inside corners of
the sills must first be
unhooked from the
interior plastic on each end. To unhook, press down firmly on the end of the Plastic Door Sill,
press firmly on the edge of the interior plastic, and pull the edge of the sill out and away from the
carpet. Repeat on the other end of the sill. Once both ends are unhooked, the sill should be
grasped from the bottom reaching between the sill and the carpet and pulling straight up. This
will require a significant amount of force. Typically the middle clip will release first after which
the end clips can be lifted or the sill slit out of the clips. Remove any of the plastic clips that
remain in the unibody with a pair of pliers and reinsert into the Plastic Door Sill.
•
Remove the screw from the plastic tab at the narrow end of the Lower Rear Plastic Trim (located
on the door jam below the Plastic Door Sill- this is why you had to take the door sill off!). Place the 2
20mm screws with 10mm washers in Bag 5.
•
Remove the screws from the inside lower center of each sides
Lower Rear Interior Trim panel (shown at right). Place the 2
single - 20mm screws with 10mm washers in Bag 5.
•
Remove the two screws along the outside edge of the upper
section of the Lower Rear Plastic Trim as pictured at the
bottom right. The two screws are located adjacent to the
Center Console metal mounting brackets exposed when the
Rear Console was removed. The front screws are 22mm and
the rear screws are 15mm both with 15mm washers. Place the
four (4) screws in Bag 5.
•
Close the soft-top and lift the Lower Rear Interior Trim over
the steel seat belt mounting posts. Once the interior has cleared the top of the post, open the softtop to lift the piece out of the car. (Note: Unplug speaker wires if applicable before removal of unit.)
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 4
INSTALL SPORTBAR/STYLEBAR MOUNTING BRACKETS
1. Installation of the Main Hoop Mounting Brackets- the main hoop
mounting brackets consists of 4 pieces:
(2) Base Mounting Brackets
(2) Mounting Posts
Each piece is specific to one location… they are not interchangeable. If they do not
seem to fit easily you have the sides interchanged. This is a new mounting design as of
January 2000 that is adapted from the BMW mounting system for the hard top
installation. Future hardtop installation can be adapted to work with these brackets so
that the hardtop and rollbar can be installed at the same time.
•
Lift out the Vinyl Covered Pads adjacent to the Soft-Top
Hinges on either side. These pads can be discarded.
•
If your car has a production date of 6/97 or later with a
manual top, it is necessary to remove the Hydraulic Lift Assist
Piston for the soft-top located under the plastic just inside and
behind the left side door jam. This can be done with a large,
flathead screwdriver by prying the piston at the top an bottom
from its ball mounts. Remove the piston entirely.
•
If you car is equipped with an electric top, you will
disconnect the piston in the same way but DO NOT
REMOVE IT FROM THE CAR OR DISCONNECT
ANY HOSES. The piston should be kept upright, wrapped
with thin foam padding and “stuffed” in behind the carpet and
padding just below and down of where it was originally located. Disconnect the power plug and
remove fuse #1 from your fuse box (in the engine compartment).
•
Using a deep 16mm deep socket remove the Upper Piston Mounting Ball. This cannot be
reinstalled as long as the rollbar is installed in the car. Remove the piston from the socket at both
the top and the bottom.
•
Remove the 10mm nut from the horizontal flange of the
Soft-Top Hinge. Set this nut aside briefly as it will be
reused as one of three points to hold down the Base
Mounting Bracket.
•
Place the left and right Base Mounting Brackets into
position next to and over the Soft-Top Hinge as shown
at right. The two holes of the bracket in the vertical plane
should line up with two existing threaded holes already
existing in the chassis.) Using a 13mm socket and open
wrench, bolt the two (2) 8mm x 15mm bolts with fixed locking
heads into the vertical positions at right. These should be fully
tightened to 30 ft.lbs.
•
Reinstall the 10mm nut from the horizontal flange of the Soft
Top Hinge (this is the nut your removed two steps before). Tighten all bolts and nuts.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 5
•
Place the Mounting Posts into position on top of the Base Mounting
Brackets as pictured to the right. Use a 17mm socket and very loosely
bolt the pieces to the Base Mounting Brackets using the 10mm x 25mm
bolts provided. The Mounting Posts must be loose to the touch so that
Roll Bar can set its own proper place. (Note that the longer part of the
bracket goes towards the front of the car. The Mounting Post does not easily
fit flush you have it on the wrong side. The brackets pictured to the right are
positioned properly. Driver’s side is on the right… the car would be facing to
the bottom of the page.)
INITIAL ALIGNMENT OF THE HMS SPORTBAR/STYLEBAR
1. Inspect and Prepare the BMW Structural Support Tube
•
Very carefully inspect the inside of each Structural Support Tube.
You are looking for excess paint around the inside top edge as well
as for weld “burn-through” inside the tube. The HMS Rollbar use
the entire depth of the tube for the rear posts. If the bar is to fit the
inside of these posts must be smooth and clear of obstructions.
•
Clean out any excess paint and/or weld burn through using a 16”
rounded metal file.
•
With two people, lift the SportBar or StyleBar into place with the main hoop over the Main Hoop
Mounting Posts, and the Rear Posts over the BMW Structural Support Tubes. Note: The bar must
be held square and lowered slowly and evenly so not to be hung up on the mounts. A large rubber
hammer can be used to free the bar or finish seating it if necessary. Use a cloth to protect the roll bar if
you are hitting directly on the bar. Remove the Billet HMS caps before pounding on the rear posts.
•
If the bar cannot be worked down without too much effort, the Support Tubes may need to be
aligned. One or both may be slightly forward or to one side. To check the side-to-side
measurement, measure the top of the rollbar at outside most points of each of the rear posts. This
should be the exact dimension as between the inside of the outside edges of the Support Tubes.
Front to rear alignment can be checked in visualizing how the main hoop fits over the Main Hoop
Mounting Posts.
•
Make certain that the bar is completely seated on the Main Hoop Mounting Posts before
proceeding. The rollbar should rest completely on the ridge around the Mounting Posts and the
10mm x 60mm bolts should be able to pass through the Main Hoop main hoop and Post with
nothing more than a light tap.
•
Once the mounting bolts have been loosely installed, the 10mm bolts that hold the Mounting Post
to the Base Mounting Bracket must be tightened. Due to the angles it is best to use a universal
swivel, 6” extension and a thin wall 17mm socket (Craftsman Professional or Snap-on seem to fit
work fine) to tighten the two bolts on each bracket.
•
Remove the bolts holding the main hoop of the rollbar to the Mounting Posts.
•
Lift the rollbar out of the car raising it slowly and evenly from both sides. If it becomes hung up,
tap it fore and aft with your hand or the rubber mallet while at the same time lifting up. It should
slide out easily once it gets started.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 6
MODIFICATION & REINSTALLATION OF INTERIOR PLASTIC TRIM
1. Modify the Lower Rear Plastic Trim
•
Install the white vinyl template provided to match the existing
contour of the Lower Rear Plastic Trim. There are two sections
on the template designed such to ensure proper alignment. After it
is aligned, remove the outer section shown by the arrow at the top
right.
•
Use a heavy lead pencil to trace around the outline of the
template onto the plastic. This will give you the area to be cut
and shaped.
•
Pull off the vinyl to prepare for cutting. (Note: Masking tape can
be used over the area that will not be cut to protect against mistakes
during the trimming process.)
•
We have found that a Roto Zip does the best for cutting out the basic shape. If you use a Roto Zip
set the cutting blade so that it is no more then ¼” exposed. Be careful in cutting the very top edge
(the “camel hump”) since this is very close from side to side. After general trimming, a Dremmel
tool works best for finishing the edges smoothly.
•
As an alternative you can use a combination of sheet metal shears, heavy-duty scissors or even a
model saw, remove the main area of the plastic. Make the cuts on the inside of the marked lines
and leave a 1/16”+/- of plastic to be shaped with the drum sander.
•
Smooth the edges and contour the curves to get a neat shape and finished appearance. Note: The
finished product will only appear as good as the time and care that you take to modify it. Take your time
and work slowly. Test fit the parts often making certain that enough plastic was removed to clear the
main hoop. The screw fasteners should be reinstalled with out distorting the plastic.
2. Reinstall Plastic Interior Trim Pieces
•
Close the soft-top.
•
Set the two Lower Rear Plastic Trim sections into place over the metal seat belt posts. Be sure not
to get the seat belt caught under trim piece. Once the trim is in place, open the soft-top.
•
Reinstall all of the screws from Bag 5 at the lower sill, lower inside, and the upper front and rear
for each side. Make certain that your modifications to the plastic trim properly clear the Main
Hoop Mounting Brackets, allowing the plastic to be fastened without distortion.
•
Feed the end of the seat belts through the Seat Belt Post Covers. Set the cover over the seat belt
post and onto the top of the Lower Rear Plastic Trim. To install the unit it must be set in at an
angle and twisted over the top of the seat belt posts. Once parallel to the lower plastic section,
push in on both sides so that the fastener tabs can be set into place. Be sure the metal screw tabs
are in place.
•
Replace the three screws and Plastic Screw Head Caps from Bag 4 on each of the Seat Belt Post
Covers. Note: If the edges of the Plastic Screw Head Caps are damaged, they can be reinstalled so the
damaged edge faces down and is out of eye site.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 7
3. Install the Rear Console
•
Close the soft-top.
•
Lift the Rear Console into place by first fitting the lower small end behind the Main Center
Console and then tilting the unit back into place.
•
Install the three screws and Trim Caps from Bag 3 along the back edge of the Rear Console.
Each of the Trim Caps has a different shape so be sure to put them in their proper locations.
•
Open the soft-top.
•
Install the two 25mm – large washer screws inside the Rear Console under where the Square
Console Covers are placed.
•
Install the two base mount screws located under the Rear Coin Tray. Be sure that the metal screw
clips are in place and properly aligned. Use a magnetic screwdriver to screw in the two 15mm
screws with 9mm washers.
•
Slide the Sub-Woofer into place and screw down with the 4 – 15mm screws from Bag 1.
•
Remount the two Square Interior Hoop Surround Covers by simply pushing them down into
place.
•
Remount the Rear Console Cover by first placing the rear plastic mounting clip into the rear slots
and then pressing down firmly on the front of the cover.
•
Place the Rear Coin Tray retaining ring through the opening in the back end of the Main Center
Console. Lift the back end of the Main Center Console and set the Rear Coin Holder into the
opening. While holding the Rear Coin Holder in place, lift the retaining ring into position and
pull the edge of the retaining ring with your fingertips. Note: The back edge of the retaining ring may
not catch the clips of the Rear Coin Holder. If this is the case after a number of attempts, remove the
parking brake handle boot. While repeating the procedure above reach through the opening for the
parking brake and grab hold of the other side of the retaining clip. Pull the retaining clip apart as the
Rear Coin Holder is held in place. The coin holder should be held in place firmly. HAVE PATIENCE YOU
CAN DO THIS!
•
Push the back end of the Main Center Console into position and install the two 20mm screws
with 12 mm washers from Bag 2 on either side of the rear of the Main Center Console.
•
Reinstall the Cassette Holder or Cup-Holder Storage Unit. Use the remaining screw and rubber
plug in Bag 2 for Storage Unit.
4. Install Roll Bar Setscrews and Access Panel Covers
•
Using the T-40 Torx wrench screw two of the Roll hoop Mounting Setscrews into each post of
the rollbar. (Note: they will only go in a short distance.)
•
Replace the Access Panel Covers by setting in the bottom edge first and then pressing in the top
edge.
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 8
LEATHER TONNEAU COVER HOLD- DOWN STRAPS
The factory Tonneau Cover can be installed in the normal manner, without modification, by fitting it
around the outside of the main hoop of the rollbar however doing this, the front Tenex Snaps on the cover
will not reach the front Tenex Attachment Pins. The Installation Kit includes two leather straps that are
used to hold down the front section of the Tonneau Cover when the bar is installed. To install and use
these straps, please follow these steps.
•
Remove the two Tenex Snaps from the front corners of the
Tonneau Cover. This is easily done by unscrewing the retaining
ring on the bottom side of the Tonneau Cover from the
threaded snap on the top. A pair of needle nose pliers inserted
into the two tiny holes on the backside of the fastener will give
you the necessary leverage to unscrew it.
•
Install the Tenex Snaps into the punched hole of each Leather
Retaining Strap. The button should be on the leather side of the
strap and the backing nut on the vinyl side of the strap.
•
Fold down the soft-top with the SportBar or StyleBar in place.
•
Locate the area where a small section of Velcro will be attached
by placing your hand between the soft-top and the rubber seal
along the fender closest to the doorjamb. You should feel a
smooth plastic surface on the inside just below the rubber edge where the soft-top is attached to the
chassis. As you raise your hand, you will feel a small smooth plastic lip and then the rubber seal.
Measure 1 ½” from the outside edge of the doorjamb, back towards the outside edge of the soft-top.
Note: before attaching the Velcro adhesive it is best to install the Tonneau cover and to attach the
Leather Retaining Straps to check your positioning. You should try to adhere the Velcro just
below the small plastic lip on the smooth, flat surface if possible. It is not a problem if some of the
Velcro is on the lip.
CLEAN THE AREA WHERE THE VELCRO WILL BE ATTACHED WITH ALCOHOL
THROUGHLY BEFORE ATTACHING. ADHESIVE WORKS BEST WHEN ALL
SURFACES ARE WARM… DO NOT INSTALL ON A COLD DAY.
•
The Leather Retaining Straps are easier to use and more effective in preventing lifting of the outside
edge of the Tonneau Cover while driving than the normal installation without the bar. They have been
track tested to 133 mph!
CONGRATULATIONS YOU HAVE COMPLETED THE INSTALLATION PROCESS!
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 9
Schedule 1
Installation Kit Packing List
SportBar /StyleBar
Aluminum trim caps (rear supports) & set screws (2 each)- installed in rollbar
“Technical Specifications & Disclaimer document"
Installation Instruction Manual
Disassembly parts storage Bags (5)
Plastic trimming template- one sheet of paper with vinyl
Tonneau cover tie down straps w/Velcro patches (2)
Main hoop Base Mounting Brackets (2 – one left side and one right side)
Main hoop Mounting Posts (2 – one left side and one right side)
17mm head – 10mm x 60mm bolts (2) – Main hoop
10mm Nyloc nuts (2) with washers (4)
17mm head – 10mm x 25mm bolts (4) – Main hoop mounting post to base bracket
13mm head - 8mm x 15mm bolts with fixed locking head (4)
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 10
Schedule 2
Suggested Tool list
Small flat head screwdriver
Short (stubby) Phillips head screwdriver
Medium length magnetic Phillips head screwdriver
3/8” drive ratchet
3/8” universal swivel attachment
3” extension
6” extension
T-40 Torx head wrench
17mm socket
16mm thin wall socket
13mm socket
10mm socket
16mm wrench
17mm wrench
13mm wrench
Hammer
Large heavy rubber hammer
Electric drill with ½” drum sander wheel or Dremmel Tool (variable speed)
Dark lead pencil
Masking tape (optional)
1.5 mm hex wrench (for aluminum cap set screws)
Large ½ round metal file – 14 to 16” (may not be needed)
Roto Zip or Sheet metal snips or heavy-duty scissors and/or model saw
A HELPER!!!
HMS motorsport SportBar and StyleBar Installation Instructions - REVISED August 2000 - Page 11