Peugeot 308: Replacement : Front wheel arch assembly

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 : Any personnel working on a vehicle with an unsafe traction battery must have received electric vehicle-specific training and be authorised to work on such vehicles.

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
• 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

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 : Remove or protect the components that are in the repair area and that can be damaged by heat or dust.

Remove :

• The bonnet
• The headlamp
• The front bumper
• The front wing
• The front mudguard
• The dashboard
• The windscreen wiper mechanism
• The power unit
• The ancillaries battery support

Release the electrical harnesses.

Replace :

• The front pillar strengthener assembly
• The front pillar upper gusset
• The front wing front mounting
• The front wing support
• The front wing upper support

4. Location of the replacement part

Identification	Description
(1)	Front wheel arch assembly

5. Identification of the replacement part

5.1. Composition : Front wheel arch assembly

Identification	Description	Thickness	Nature/classification
(1)	Front wheel arch assembly	-	-
(1a)	Front wheel arch - front part	0,95 mm	High strength (HSS)
(1b)	Front wheel arch front strengthener	1,45 mm	Ultra high strength (UHSS)
(1c)	Front suspension support	2,8 mm	Very high strength (VHSS)
(1d)	Plenum chamber stiffener	0,95 mm	High strength (HSS)
(1e)	Front wheel arch	1,10 mm	Very high strength (VHSS)
(1f)	Front wheel arch closing panel	1,12 mm	Very high strength (VHSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Lower bulkhead	1,15 mm	High strength (HSS)
(3)	Scuttle closing panel central stiffener	1,05 mm	Very high strength (VHSS)
(4)	Scuttle closing panel lower part	0,80 mm	High strength (HSS)
(5)	Scuttle spacer	1,25 mm	High strength (HSS)
(6)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(7)	Wheel arch upper connection	1,45 mm	High strength (HSS)
(8)	Front chassis leg bracket	1,47 mm / 1,95 mm	Very high strength (VHSS) / High strength (HSS)

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

6. Preparation of the replacement parts

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").

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 parts on the body

Level off the MIG weld beads(at "a").

Cut out the spot welds .

Cut out the spot welds .

Cut :

• The spot welds
• The spot weld in 2 thicknesses(at "b")

Cut :

• The spot welds
• The spot welds in 2 thicknesses(at "c")

Cut :

• The spot welds
• The spot welds in 2 thicknesses(at "d")

Detach the front wheel arch assembly at the beads of structural adhesive ; Using a hot air gun.

Remove the front wheel arch 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.

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.

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".

Apply a structural adhesive index "B3".

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The front wheel arch assembly
• The components for adjusting

Check :

• The position; using one of the approved measuring systems
• The fits and clearances

Support the parts in 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 :

• By means of MAG plug welds
• By MIG weld beads(at "e")

Grind the MAG plug welds.

N.B. : Do not grind the MIG beads.

Weld with MAG plug welds.

Grind the MAG plug welds.

Weld :

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

Grind the MAG plug welds.

Weld :

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

Grind the MAG plug welds.

Weld :

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

Grind the MAG plug 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 .

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

Reconnect the ancillaries batteries (Following the specific procedure ).