Safety precautions and general information

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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 REMOVING HEADLINING (WITH SLIDE/TILT SUNROOF) or REMOVING HEADLINING (WITHOUT SLIDE/TILT SUNROOF) .

IMPORTANT: Lay out protective mats to protect the interior against debris 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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Drill off the rivet plate (1) down to rivet shank with a 10 mm twist drill bit.

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 Rivet Plate And Bracket

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Deburr remaining rivets with nipper pliers.

Fig 3: Removing Rivets With 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 body below attachment point.

Fig 6: 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 7: Positioning Special Tool From Rear On Rivet Head

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Installation note:

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

Avoid rivet inclination.

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 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.

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 Mark On End Of Tube

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