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

Special tools required: 

• 72 1 200

Necessary preliminary tasks: 

• Disconnect battery negative lead
• Follow instructions  for unlocking and locking airbag plug connections
• Remove roofliner

Fig 1: Passenger Compartment Protective Mat Covering

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Overview of head airbag: 

Fig 2: Head Airbag Components And Assembly

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Head airbag installation summary: 

Fig 3: Head Airbag Installation Position And Assembly

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• When removing blind rivet 3 or 8, 100 % foaming is necessary
• When removing blind rivet 4, also replace blind rivets 3 and 5
• When removing blind rivet 7, also replace blind rivet 6
• 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

Rivet heads 1, 2, 4 and 7 can be collected with special tool 72 1 200.

Rivet heads 3 and 8 cannot be accessed with special tool; cavity has to be filled with foam beforehand.

Rivet heads 5 and 6 - no special tool required.

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

Fig 4: Drilling Rivet Plate

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

Remove gas generator with B-pillar ramp.

Fig 5: Removing Folding Pack With Plastic Wedge From Body

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

Fig 6: Cutting Blind Rivet To Sheet Metal

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Deburr remaining rivets with nipper pliers.

Fig 7: Removing Remaining Rivets With Nipper Pliers

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Installation: 

Apply primer to damaged paintwork on side frame.

Removing rivet heads 5 and 6: 

Stabilize metal tab with screwdriver (1).

Drive out rivet head with 6 mm punch.

Fig 8: Removing Metal Tab With Screwdriver

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Removing rivet heads 1,, 2, 4 and 7: 

Special tool 72 1 200 for collecting rivet remnants.

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

Fig 9: Special Tool (72 1 200)

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

Fig 10: Inserting Special Tool (72 1 200) Bore In Body

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Position special tool from rear on rivet head in cavity.

Fig 11: Special Tool On Rivet Head

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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 12: Identifying Special Tool On Rivet Head

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Preparing tube for foam can: 

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

Cut end of tube (1) at an angle.

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

Fit tube to foam can.

Recycling: 

Empty foam can completely onto cardboard and after hardening dispose of foam and can in residual waste.

Fig 13: Tubes And Marking

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Filling rivet heads 3 and 8 with foam: 

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

Fill cavity in an operation lasting 5 seconds.

Fig 14: Locating A-Pillar Hole

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Insert tube through screw fastening point for B-pillar seat belt and slide in upwards up to marking.

Fill cavity in an operation lasting 3 seconds.

Fig 15: Inserting Tube Through Screw

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Driving through rivet heads 3 and 8:

Drive out rivet head with a 6 mm punch.

Rivet remnants drop into foam nest (1) in B-pillar cavity and remain there.

Fig 16: Riveting Remnants Drop Into Foam Nest In B-Pillar Cavity And Remain There

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Drive out rivet head with a 6 mm punch.

Rivet remnants drop into foam nest (1) in A-pillar cavity and remain there.

Fig 17: Riveting Remnants Drop Into Foam Nest In A-Pillar Cavity And Remain There

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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 gas generator housing with:

1. Riveting of holders for folding pack:

   17/36 nosepiece and short shank

2. 17/40 nosepiece and long shank
   Fig 18: 17/36 Nosepiece And Short Shank - 17/40 Nosepiece And Long Shank

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Sequence of riveting process for head airbag: 

Gas generator riveted twice with blind rivet dia. 6 mm.

1. Rivet bore
2. Rivet elongated hole
   Fig 19: Drilling Blind Rivet

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Holders for folding pack riveted 7 times with blind rivet dia. 6.4 mm.

Installation: 

Avoid rivet inclination.

Fig 20: Drilling Blind Rivet

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