51 16... Removing and installing grab handle holder

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Special tools required:

2 348 128
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:

Lower HEADLINING completely

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: Protective Mats

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

Unscrew holder (2).

Fig 2: Rivet Plate And Holder

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Front holder:

NOTE: Folded package of head airbag conceals bottom rivet point.
Carefully raise folded package to expose rivet point.

DRILL OUT rivets.

Remove holder for grab handles.

Fig 3: Rivet

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Rear holder:

NOTE: Folded package of head airbag conceals bottom rivet point.
Carefully raise folded package to expose rivet point.

DRILL OUT rivets.

Remove holder for grab handles.

Fig 4: Rivet Point

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Deburr remaining rivets with nipper pliers.

Installation note:

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

Fig 5: Removing Rivets With Nipper Pliers

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Removal of the top rivet heads (1):

Press off rivet heads (1) using special tool 2 348 128 and remove.

Fig 6: Pressing Rivet Heads Using Special Tool (2 348 128)

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Removal of the bottom rivet heads (1):

Use 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 7: Rivet Heads

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

Fig 8: Inserting Special Tool (72 1 200) Into Bore Hole Of Body

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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 9: Position Special Tool On Rivet Head

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NOTE: If the rivet head 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.
Use cavity foam for foam filling.

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.

Fig 10: Foam Can Tube Mark

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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.