Peugeot 308: Replacement : Front bumper absorber support

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be isolated by an authorised technician.

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the precautions to be taken for the pyrotechnic components .

ESSENTIAL : All personnel carrying out work on a vehicle fitted with traction batteries must have received specific electric vehicle training and be authorised to work on these vehicles (observe the regulations in force in the respective country).

CAUTION : All of the stripped surfaces must be protected by means of the approved electrolytic rezincing process .

CAUTION : The number of spot welds or weld beads required for assembling a new component must be identical to the number of spot welds or weld beads attaching the original component.

1. Information

Types of spot welds or beads using the electric arc process :

• MIG braze welding with cupro-aluminium filler used with an inert gas
• MAG welding with steel filler metal and active gas

Designation of the high strength panels :

• High strength (HSS) : High strength steel
• Very high strength (VHSS) : Very high strength steel
• Ultra high strength (UHSS) : Ultra high strength steel

N.B. : Use the products recommended by the manufacturer .

2. Tooling

Workshop equipment : Swan’s neck drill for cutting out electric spot welds.

Tool	Reference	Description
	[1366-ZZ]	Toolkit for testing electric spot welds
	[1366]	Samples for testing electric spot welds
	[1126]	Set of drill bits for removing spot welds

3. Preliminary operations

ESSENTIAL : Deactivate the pyrotechnic systems .

CAUTION : Perform the operations that are required before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure ).

CAUTION : Either remove or protect those components which are in the repair zone and risk being damaged by the heat or the dust.

Remove :

• The front bumper
• The headlamp
• The front bumper frame
• The front panel upper crossmember
• The lower crossmember of the front panel
• The engine cooling radiator

Release the electrical harnesses.

Replace the engine compartment front panel support .

4. Location of the replacement part

Marking	Description
(1)	Front bumper absorber support

5. Identification of the replacement part

5.1. Composition : Front bumper absorber support

Marking	Description	Thickness	Nature/classification
(1)	Front bumper absorber support	3 mm	Very high strength (VHSS)

5.2. Identification of the parts adjacent to the replacement part

Marking	Description	Thickness	Nature/classification
(2)	Front chassis member front section	1,76 mm	High strength (HSS)
(3)	Chassis member bracket (front section)	1,47 mm	High strength (HSS)

6. Replacement part preparation

CAUTION : When cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection.

Prepare the mating edges and protect them using a weldable primer (Index "C7").

N.B. : Apply the weldable primer on the internal faces of the panels to be welded.

7. Cutting of the part on the body

Grind away the MAG weld beads.

Cut out the spot welds (In "a").

Remove the front bumper absorber support .

8. Cleaning and preparation of the body

CAUTION : When cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection.

Prepare the mating edges and protect them using a weldable primer (Index "C7").

N.B. : Apply the weldable primer on the internal faces of the panels to be welded.

9. Adjustment

Position :

• The front bumper absorber support
• The components for adjusting

Clamp the part into position.

10. Welding

CAUTION : Set the welding station.

Setting of the welding station :

• Electric spot weld testing ; Using the tool [1366-ZZ]
• Samples for testing electric spot welds ; Using the tool [1366]

CAUTION : The number of spot welds or weld beads required for assembling a new component must be identical to the number of spot welds or weld beads attaching the original component.

"A" = 15 mm.

Weld :

• By MAG weld bead (at "b")
• By means of MAG plug welds (at "c")

"B" = 50 mm.

Weld by MAG bead (at "d").

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Sealing mastic (index "A1")

Painting, then spraying of the index "C4" product into the hollow sections in the repair zone.

12. Additional operations

Refit the electrical harnesses and reinstall all removed components.

13. Reinitialisation

ESSENTIAL : Reactivate the pyrotechnic systems .

CAUTION : Perform the operations that are required after reconnecting the ancillaries batteries .

Reconnect the ancillaries batteries (Following the specific procedure ).