09-002/03 2002-2003.5 PROTEGE5 ROOF RACK CROSS BAR REMOVAL & INSTALLATION INSTRUCTIONS

APPLICABLE MODEL(S)/VINS

2002- 2003.5 Protege5 (factory equipped with roof rails and cross bars)

DESCRIPTION

If a vehicle was factory equipped with the roof rack side rails, the cross bars can be removed or installed. Please follow the instructions below for removal and installation of the cross bars.

NOTE: The roof rack must be equipped from the factory. The roof rack cannot be installed as an accessory. Mid year 2003 the roof rack cross bars will no longer be installed on the vehicle at the port, they will be shipped in the trunk of the vehicle, to be installed at the "customers discretion".

CAUTION:

• All warnings and cautions apply to technicians and customers using these instructions.
• This installation requires two persons to avoid damaging the vehicle.
• Wear work gloves to prevent hand injuries from sharp edges or tools.
• Tighten all bolts evenly from side to side to prevent damage to the roof rack or leaning causing distortion of the rack and making the rack crooked.
• Carefully observe all torque specifications.
• The maximum load capacity of the roof rack is 75 kg (165 lb) and must be evenly distributed across the entire roof.
• The roof rack is not designed for direct loading, special accessory attachments are available from your local Mazda dealer.
• When using an accessory kit, always follow all instructions included with the accessory kit.
• Because bolts and screws may loosen in use, periodically check torque and tightness of all bolts and screws every 100 km (62 miles).

NOTE: The cross bars can only be installed in a vehicle that came from the factory with the side rails installed.

ROOF RACK PARTS

#)	Description	Qty	#)	Description	Qty
(1)	Front Cross Bar	1	(6)	Rear Rail Forward Cover	1/side
(2)	Rear Cross Bar	1	(7)	Rear Rail Back Cover	1/side
(3)	Front Cross Bar Upper Cover	1/side	(8)	Bolt (M8, L16) pre-coated with blue threadlock	2
(4)	Front Cross Bar Lower Cove	1/side	(9)	Finisher Screw (M4)	4
(5)	Rear Cross Bar Upper Cover	1/side

TOOL LIST

Description

Flat Blade Screwdriver

Phillips Screwdriver #)2

12mm Combination Wrench

12mm Socket

Torque Wrench (inlb)

INSTALLATION INSTRUCTIONS

1. Remove the four finisher caps:

   CAUTION: Use care not to scratch the vehicle, wear work gloves to avoid hand injury.

   1. Insert a flat head screwdriver in the gap between the cap and the roof rack.
   2. Lift the cap up and remove it.

      NOTE: Keep the finisher panels, they will be required if the cross bars are ever removed.

   

2. Gently place the cross bar (1) on the vehicle with the "notch" to front of vehicle.

   WARNING: This step requires two people. Take care not to scratch the vehicle.

   

3. Adjust the length of cross bar bracket to align installation holes.

   

4. Install and tighten bolts (8) alternating, evenly on both sides.

   NOTE: If one bolt is tightened and then the other, the cross bar will lean to one side distorting the rails and making the rack crooked, tighten the bolts evenly to prevent distortion.

   1. Torque the bolts to 11-12Nm (97-106 lbin).

   

5. Install lower cross bar cover (4). Move the cover in the direction shown by the arrow "a" and lift it up in the directions shown by arrow "b" to assemble the cover.

   

6. Install the Front Cross Bar Upper Cover (3) by engaging its clips in the square holes in the roof rack until they click.
   1. Tighten screws (9) to 0.3-0.5 Nm (2.6-4.4 lbin).

   

7. Adjust both sides of the front cross bar to have the same clearance between the "bead" and the cross bar cover (approximately 9mm (0.35 inch)).
   1. Tighten the 4-bolts on back of the cross bar to 7-8 Nm (62-71 lbin).

      

8. Place the rear cross bar into position:

   NOTE: This step requires two-people. Take care not to scratch the vehicle.

   1. Make sure the crossbar and hardware are positioned correctly.
   2. Install both sliding brackets into the front groove of the rear cross bar track at the same time and slide them toward the rear of the vehicle.

   

   WARNING: Take extra time to double check that the roof rack is secure - pull on the rack at each corner to check it . If the rack is not secured, the side rails or cargo can fly off the vehicle and cause an accident.

9. Install the Rear Rail Forward Cover (6) and Rear Rail Back Cover (7). :

   CAUTION: Make sure rail covers are properly installed to prevent them from coming loose while driving.

   

10. Position the Rear Cross Bar (2) as shown below:
    • Tighten the bolts alternately and evenly

      NOTE: If only one bolt is tightened and then the other, the cross bar will lean to one side distorting the rails and making the rack crooked, tighten the bolts evenly to prevent distortion.

      WARNING: Take extra time to double check that the roof rack is secure - pull on the rack at each corner to check that it is secure. If the rack is not secured, its components the side rails or cargo can fly off the vehicle and cause an accident.

    • Torque to bolts to 11-12 Nm (97-106 lbin)

    

11. Install both Rear Cross Bar Upper Cover (5) with Finisher Screw (9).
    • Tighten to 0.3-0.5 Nm (2.6-4.4 lbin).

      

12. Adjust both sides of the rear cross bar to have the same clearance between the "bead" and the cross bar cover (approximately 9mm (0.35 inch)).

    

13. Tighten the four bolts on the back of the rear cross bar:
    • Torque to 7-8 Nm (62-71 lbin).

      

14. Shake the roof rack up and down and side to side to verify there is no vibration or looseness. If the roof rack moves, reconfirm the installation procedure and all torque specifications.

    

REMOVAL INSTRUCTIONS

1. Reverse the installation instructions observing the following notes:
   1. Remove all loads and attachments from the roof rack.
   2. Use care not to damage the vehicle.
   3. Wear gloves to protect your hands from injury.
   4. When loosening bolts on opposite sides of the vehicle, loosen them alternately and evenly.
   5. Clean the roof rack and store it in a dry place.
   6. Keep the installation instructions in a safe place.

WARRANTY INFORMATION

NOTE: The roof rack is optional equipment, installation and removal of the cross bars is not covered underwarranty.