51 16... Removing and installing grab handle holder

Special tools required:

72 1 200

WARNING: FOLLOW SAFETY INFORMATION FOR REPAIR WORK ON VEHICLES WITH AIRBAG SYSTEMS .

IMPORTANT: RISK OF DAMAGE! DO NOT USE SHARP TOOLS IN THE AREA OF THE HEAD AIRBAG .

Necessary preliminary tasks:

Remove headlining . See 51 44 011 REMOVING AND INSTALLING/REPLACING HEADLINING (VERSION WITH SLIDE/TILT SUNROOF) or 51 44 001 REMOVING AND REFITTING/REPLACING ROOFLINER (VERSION WITHOUT SLIDING/TILTING SUNROOF)

IMPORTANT: Lay out protective mats to protect the interior against swarf from the drilled-out rivets and damage.
Lay out protective mats in the relevant working area:

Dashboard
Entrance area
Passenger compartment

Fig 1: Identifying Dashboard Protective Mats

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Drill off the rivet plate (1) down to rivet shank with a 10 mm twist drill bit.

Only on F01, F02 and F04:

Bracket (2) has two rivets (1) at the top and one screw (1) at the bottom.
Tightening torque 51 16 23AZ .

Unscrew holder (2).

Fig 2: Identifying Handle Holder Rivet Plate And Bracket

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Deburr remaining rivets with nipper pliers.

Fig 3: Removing Rivets Using Nipper Pliers

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Installation note:

Lay out possible paintwork damage on the side frame with primer.

Removal of the top rivet heads (1):

Stabilize sheet metal tab with screwdriver.

Drive out rivet heads with punch.

Fig 4: Identifying Top Rivet Heads

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Removal of the bottom rivet heads (1):

Special tool 72 1 200 for collecting rivet remnants.

Shank of special tool is flexible and can be adapted to the relevant body contours.

NOTE: Insert butyl in collecting tray to secure rivet remnants against falling out.

Fig 5: Identifying Bottom Rivet Heads

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Insert special tool 72 1 200 through bore hole in the body underneath the attachment point.

Fig 6: Inserting Special Tool (72 1 200)

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Position special tool from rear on rivet head in cavity.

NOTE: Make sure collecting tray is correctly fitted on rivet head.

A second person will be needed to help hold the special tool on the rivet head during the driving-out operation.

With hammer and punch drive out stem into collecting tray.

Carefully maneuver special tool out of body so that rivet head does not fall out of collecting tray.

Fig 7: Positioning Special Tool (72 1 200)

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NOTE: If the rivet falls out of the collecting tray into the side frame when the special tool is fed out, this area must be generously filled with foam.

For details of procedure for filling cavities with foam, see further operations.

Preparing tube for foam can:

Slide hose (1) at least 6 cm into hose (2).

Cut end of hose (1) at an angle.

Mark (3) is not required.

Fit hose to foam can.

Run hose into corresponding opening in body.

Fill cavity in an operation lasting 0, 5 seconds.

WARNING: Empty foam can completely onto cardboard and after hardening dispose of foam and can in residual waste.
Can may burst if not completely emptied.

Fig 8: Identifying Handle Holder Hose And Mark

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