Peugeot 308: Replacement : Front pillar

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be disconnected electrical supply.

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
• Hot air blower

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
	[FEIN-400E]	"FEIN-400E" electric knife kit-"C1" electric knife-"C2" "FEIN" offset hub saw blade-"C3" Blade no. 103

3. Preliminary operations

ESSENTIAL : Deactivate the pyrotechnic systems .

CAUTION : Perform the operations that are required prior to a disconnection of the ancillaries battery .

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Disconnect the ancillaries battery or batteries.

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 door
• The front door aperture seal
• The bonnet
• The front wing
• The interior trims
• The windscreen
• The body sill plugs

Release the electrical harnesses.

Replace :

• The windscreen trim
• The front wing upper support
• The front wing lower support
• The passenger compartment side front strengthener expanding insert
• The windscreen pillar expanding insert
• The front pillar exterior expanding insert
• The sill front closer expanding insert

4. Location of the replacement part

Identification	Description
(1)	Front pillar

5. Identification of the replacement part

5.1. Composition : Passenger compartment side front part

Identification	Description	Thickness	Nature/classification
(1)	Passenger compartment side front part	0,64 mm	Mild steel

N.B. : The front pillar is extracted from the body side front part.

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(3)	Front pillar upper gusset	1,20 mm	Very high strength (VHSS)
(4)	Windscreen pillar inner panel	1,10 mm	Ultra high strength (UHSS)
(5)	Windscreen pillar strengthener	1,10 mm	Ultra high strength (UHSS)
(6)	Sill strengthener	1,15 mm	Ultra high strength (UHSS)
(7)	Central interior sill	1,35 mm	Very high strength (VHSS)
(8)	Front interior sill	1,35 mm	Very high strength (VHSS)
(9)	Front pillar strengthener	1,25 mm	Ultra high strength (UHSS)

CAUTION : Take into account the difference in thickness of the parts when adjusting the welding station.

6. Replacement part preparation

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

Mark (at "a", "b") in the cutting zone "A", "B" then cut .

N.B. : The cutting lines "a" and "b" are given as an indication only and may change according to the different cases of replacement of the front pillar.

Mark then drill to a diameter of 7 mm for later plug welding.

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

Mark (at "c", "d") in the cutting zone "C", "D" then cut .

N.B. : The cutting lines "c" and "d" are given as an indication only and may change according to the different cases of replacement of the front pillar.

Cut out the spot welds .

Cut out the spot welds .

Detach the front pillar at the expanding inserts ; Using a hot air gun.

Remove the front pillar .

8. Cleaning and preparation of the body

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.

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.

Seal the expanding inserts (10), (11), (12), (13) .

9. Adjustment

Position :

• The front pillar
• The components for adjusting

Check the fits and clearances .

Adjust the cuts (if necessary).

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.

Weld with MAG beads.

Grind the MAG weld beads.

Weld :

• With electric spot welds
• By means of MAG plug welds (at "e")

Grind the MAG plug welds.

Weld with electric spot welds.

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Sealing mastic (index "A1")
• Anti-chip protection (index "C4")

Painting, then spraying of the index "C5" 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 .

Restore the voltage supply to the vehicle.

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

CAUTION : In the case of a vehicle with 2 batteries, carry out the specific operations for disconnecting and reconnecting the ancillaries batteries.

Reconnect the ancillaries battery or batteries.