72 12 060 Removing and installing or replacing left or right head airbag

Special tools required:

72 1 210

WARNING: Read and comply with SAFETY INSTRUCTIONS for handling airbag modules and pyrotechnical belt tensioners.
Incorrect handling can activate airbag and cause injury.

Necessary preliminary tasks:

Disconnect BATTERY NEGATIVE CABLE
Follow INSTRUCTIONS for unlocking and locking airbag plug connections
Remove HEADLINING

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

Dashboard
Entrance area
Passenger compartment

Fig 1: Identifying Protective Mats

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Overview of head airbag:

Fig 2: Overview Of Airbag Modules, Seat Belts, Airbag Sensors And Airbag Control Unit

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Unfasten PLUG CONNECTION (1) and disconnect.

Fig 3: Identifying Airbag Plug Connection

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Drill following off rivet plate down to rivet shank with a 10 mm twist drill bit.

IMPORTANT: Observe following sequence:

Fig 4: Drilling Off Rivet Plate Down To Rivet Shank

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Drill open front rivet plate.

Drill open rear rivet plate.

Fig 5: Locating Rivet Plates

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Fig 6: Identifying Inertia Reel Unit Screw

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IMPORTANT: Risk of damage to holders and folding pack.

Carefully lever out holders for folding pack from body with plastic wedge.

Fig 7: Pulling Out Holders For Folding Pack With Plastic Wedge

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Unfasten screws (2).

Tightening torque 72 12 03AZ .

Remove head airbag.

Fig 8: Identifying Head Airbag Screws

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In the event of a bent or faulty pin or apparent riveting when the gas generator is removed, it will be necessary to replace the complete head airbag

NOTE: It is permitted to replace individual rivets without replacing the complete head airbag.

Remove shafts of blind rivets flush with panel (holder of handle).

Fig 9: Cutting Off Blind Rivet Shanks

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Deburr remaining rivets with nipper pliers.

Use hammer and 6 mm punch to drive out rivet stem.

NOTE: Remove rivet heads only from the holders of the grab handle.

Fig 10: Removing Rivets With Nipper Pliers

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Installation note:

Apply primer to damaged paintwork on side frame.

Remove all rivet residues.

Rivet head (1) must be caught with special tool when removing it from the body.

Fig 11: Identifying Rivet Head

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Special tool 72 1 210 for collecting rivet remnants.

Shank (1) of special tool is flexible and can be adapted to the relevant body contours.

NOTE: Insert butyl in collecting tray (2) to secure rivet remnants against falling out.

Fig 12: Identifying Shank And Collecting Tray

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Insert special tool 72 1 210 through bore hole in body next to attachment points.

Position special tool from rear on rivet head in cavity.

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

Make sure collecting tray is correctly fitted on rivet head.

Fig 13: Inserting Special Tool (72 1 210) Through Bore Hole In Body

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Drive out stem with hammer and 6 mm punch.

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

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.

Use cavity preservation (obtainable via BMW) for foam filling.

Cavity foam can also be used if necessary.

Preparing tube for foam can:

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

Cut end of hose (1) at an angle.

Apply marking (3) 15 cm from end of hose.

Fit hose to foam can.

Fig 14: Identifying Foam Can Hose And Mark

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Foaming the rivet head:

Slide in hose through A-pillar hole up to marking from the top down.

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 15: Filling A-Pillar Hole Cavity

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Overview of rivet gun:

Riveting of gas generator housing and holders for folding pack with rivet gun.

The interchangeable head is changed for the different work operations.

Riveting of holders for folding pack:

2.) 17/40 nosepiece and long shank

Fig 16: Identifying Nosepieces And Shanks

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Holders for folding pack riveted 5 times with blind rivet dia. 6.4 mm.

Installation note:

Avoid rivet inclination.

Fig 17: Drilling Blind Rivet

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