TOROS Roof Rack Cross Bars Instruction Manual

1. Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your TOROS Roof Rack Cross Bars. Designed for the Hyundai Ioniq 5 (2022-2025) with a bare/normal roof, these cross bars offer a robust solution for transporting cargo.

Important Compatibility Note: These roof rack cross bars are specifically designed for Hyundai Ioniq 5 models from 2022 to 2025 that feature a bare or normal roof. They are not compatible with models equipped with flush or integrated roof rails. Please verify your vehicle's roof type before proceeding with installation.

2. Package Contents

Please ensure all components are present before beginning installation:

• 3 x Aluminum Cross Bars
• Mounting Brackets (6 units for 3 bars)
• Nuts and Bolts
• Lockable System with Keys
• Installation Tools (Hex keys, etc.)
• Protective Pads/Stickers

Figure 1: All components included in the TOROS Roof Rack Cross Bars package.

3. Specifications

4. Installation Guide

Follow these steps carefully for proper installation. It is recommended to have a second person assist during certain stages.

4.1. Video Installation Guide

The video above provides a comprehensive visual guide for the installation. Please refer to it for detailed demonstrations of each step. The following sections provide a summary and additional tips.

4.2. Step-by-Step Installation

1. Unboxing and Component Check:

   Carefully unbox all components. Lay them out and verify against the package contents list. Ensure all brackets, bolts, nuts, and cross bars are present.

   

   Figure 2: All parts laid out for inspection after unboxing.

2. Assemble Cross Bar Mounts:

   Attach the mounting feet to the aluminum cross bars. Ensure the bolts are finger-tightened only at this stage, allowing for adjustments later. The T-slot system allows for flexible positioning.

   

   Figure 3: Attaching the mounting feet to the cross bars.
3. Prepare Vehicle Roof:

   Clean the areas on your vehicle's roof where the mounting feet will make contact. Apply the provided protective stickers or pads to prevent scratches and ensure a secure fit. These should be placed along the door frame where the clamps will grip.

   

   Figure 4: Applying protective stickers to the vehicle's roof edge.

4. Position Cross Bars:

   Carefully place the assembled cross bars onto the vehicle's roof. Ensure the rounded side of the cross bar faces the front of the vehicle for optimal aerodynamics. Adjust the position of the mounting feet to align with the door frames.

   

   Figure 5: Correct positioning of the cross bars on the vehicle roof.

5. Secure Mounting Brackets:

   Engage the clamp-on mechanism by tightening the bolts on each mounting foot. Tighten gradually and evenly on both sides. Ensure the clamps securely grip the door frame without damaging the vehicle's paint or seals. A small gap may be present initially, which will close as the bolts are fully tightened.

   

   Figure 6: Securing the mounting brackets to the vehicle.
6. Final Tightening and Alignment:

   Once all cross bars are in place, perform a final tightening of all bolts. Ensure the cross bars are parallel and evenly spaced. Check for any movement by gently shaking the installed rack. The vehicle should move with the rack, indicating a secure fit. If necessary, loosen bolts slightly to adjust the head bracket angle for a perfect fit, then re-tighten.

   

   Figure 7: Fully installed roof rack system.

7. Install Locking Covers:

   Place the lockable covers over the mounting feet. Use the provided keys to lock them, securing the cross bars and preventing unauthorized removal. If there are any excess plastic pieces from the protective pads, trim them for a clean finish.

   

   Figure 8: Installing the lockable covers for security.

5. Operating Instructions

• Load Capacity: Do not exceed the maximum load capacity of 330 lbs (150 kg) for the cross bars. Distribute weight evenly across all bars. Overloading can compromise vehicle stability and safety.
• Aerodynamic Design: The cross bars feature an aerodynamic design to minimize wind noise and drag. Ensure the rounded edge faces forward during installation.
• T-Slot System: Utilize the integrated T-slot system for easy attachment of various roof-mounted accessories such as cargo boxes, bike racks, or kayak carriers.
• Security: Always ensure the lockable covers are properly secured with the provided keys to prevent theft of the cross bars and any mounted accessories.
• Driving with Load: When carrying cargo, drive at reduced speeds, especially in windy conditions or on uneven terrain. Avoid sudden braking or sharp turns.

6. Maintenance

• Regular Inspection: Periodically check all bolts, nuts, and mounting points for tightness. Re-tighten if any looseness is detected.
• Cleaning: Clean the cross bars and mounting feet regularly with mild soap and water. Avoid abrasive cleaners that could damage the finish.
• Corrosion Prevention: The high-grade aluminum alloy is designed to be rust-proof and corrosion-resistant. However, regular cleaning and inspection, especially after exposure to salt water or harsh chemicals, will prolong its lifespan.
• Seasonal Removal: If the roof rack is not needed for extended periods, consider removing it to reduce wear and tear and potentially improve fuel efficiency.

7. Troubleshooting

8. Warranty and Support

For warranty information or technical support, please refer to the contact details provided with your purchase or visit the official TOROS website. Keep your proof of purchase for any warranty claims.