Peugeot 308: Replacement : Front pillar strengthener assembly

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
• Electronic measurement system
• Mechanical measurement system

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 windscreen
• The bonnet
• The front door
• The front wing
• The windscreen wiper mechanism
• The dashboard

Release the electrical harnesses.

Replace :

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

4. Location of the replacement part

Identification	Description
(1)	Front pillar strengthener assembly
(2)	Exterior expanding insert for the front strengthener of the passenger compartment side
(3)	Front pillar interior expanding insert
(4)	Front pillar exterior expanding insert
(5)	Sill front closing panel expanding insert
(6)	Interior expanding insert for the front strengthener of the passenger compartment side

5. Identification of the replacement part

5.1. Composition : Front pillar strengthener assembly

Identification	Description	Thickness	Nature/classification
(1)	Front pillar strengthener assembly	-	-
(1a)	Front pillar upper gusset	1,20 mm	High strength (HSS)
(1b)	Front pillar strengthener	1,25 mm	Ultra high strength (UHSS)
(1c)	Front pillar bottom hinge strengthener	4,00 mm	High strength (HSS)
(1d)	Front door hinge tapping plate	4,00 mm	High strength (HSS)
(1e)	Dashboard crossmember lateral support	2,50 mm	High strength (HSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(7)	Windscreen pillar inner panel	1,30 mm	Ultra high strength (UHSS)
(8)	Windscreen pillar strengthener	1,10 mm	Ultra high strength (UHSS)
(9)	Side member strengthener assembly	2,00 mm	Ultra high strength (UHSS)
(10)	Front interior sill	1,35 mm	Very high strength (VHSS)
(11)	Front jacking point	1,50 mm	Very high strength (VHSS)
(12)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(13)	Lower bulkhead	1,15 mm	High strength (HSS)
(14)	Windscreen lower cross member	0,95 mm	High strength (HSS)

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 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.

Seal the expanding inserts (2), (3), (6) .

7. Cutting of the part on the body

Cut :

• The spot welds
• The spot welds over 2 thicknesses (at "a")

Cut out the spot welds .

Cut :

• The spot welds
• The spot welds over 2 thicknesses (at "b")

Detach the front pillar strengthener assembly at the expanding inserts ; Using the hot air blower.

Remove the front pillar strengthener assembly.

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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The front pillar strengthener assembly
• The components for adjusting

Check the position using one of the approved measurement systems.

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 electric spot welds.

Weld with electric spot welds.

MAG plug weld.

Grind the MAG plug welds.

Weld :

• By means of MAG plug welds
• By means of MAG plug welds in 2 thicknesses (at "c")

Grind the MAG plug welds.

N.B. : The remaining spot welds will be done during welding of the front pillar assembly .

Clip in the expanding inserts (4), (5) .

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• 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.