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

Special tools required:

72 0 020
72 1 200

WARNING: Observe SAFETY REGULATIONS when handling airbag modules.
Incorrect handling can activate airbag and cause injury.

Switch off the ignition!

Necessary preliminary tasks:

Remove HEADLINING
Disconnect BATTERY EARTH LEAD

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 Protective Mats
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Overview of head airbag:

Fig 2: Overview Of Head Airbag

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To detach the clamps, use special tool 72 0 020 .

Push the left and right tabs together and pull clamp out.

Fig 3: Detaching Clamps Using Special Tool (72 0 020)

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Unlock and remove clamps (1) with flat-nose pliers.

Fig 4: Locating Clamps

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Unlock and remove clamps (1) with flat-nose pliers.

Fig 5: Locating Clamps

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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 6: Drilling Rivet Plate

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Drill open front rivet plate.

Fig 7: Identifying Front Rivet Plate

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Drill out rear rivet plate (1).

Fig 8: Identifying Rear Rivet Plate

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Unfasten plug connection (1) and disconnect.

Drill out rivets (2).

Installation note:

Gas generator is coded against incorrect assembly.

Fig 9: Identifying Rivets And Plug Connection

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IMPORTANT: Risk of damage to holders and folding pack.

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

Remove gas generator with B-pillar ramp.

Fig 10: Removing Gas Generator With B-Pillar Ramp

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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.

Cut off blind rivet shanks down to sheet metal as level as possible.

Fig 11: Cutting Blind Rivet Shanks

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Deburr remaining rivets with nipper pliers.

Fig 12: Removing Rivets Using Nipper Pliers

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Installation note:

Apply primer to damaged paintwork on side frame.

Remove all rivet residues.

Removing rivet heads:

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 13: Identifying Holder (72 1 200)

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

Fig 14: Inserting Special Tool (72 1 200) Through Bore Hole In 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.

Fig 15: Positioning Special Tool From Rear On Rivet Head In Cavity

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

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.

Fig 16: Identifying Special Tool On Rivet Head

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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.
Use cavity preservation 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 17: Identifying Hose And Tube For Foam Can

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Foaming of 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 18: Filling A-Pillar Hole Cavity