Peugeot 308: Replacement : Front wing inner panel 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 repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person.

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
• Mechanical measurement system
• Electronic 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 : 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 front mudguard
• The dashboard
• The windscreen wiper mechanism

Release the electrical harnesses.

Replace :

• The passenger compartment side front part
• The front wing upper support (Rear section)
• The front pillar strengthener assembly
• The front pillar upper gusset
• The windscreen pillar strengthener
• The windscreen pillar stiffener
• The passenger compartment side front strengthener exterior expanding insert
• The passenger compartment side front strengthener expanding insert
• The windscreen pillar interior expanding insert
• The passenger compartment side front closing panel expanding insert
• The windscreen pillar exterior expanding insert

4. Location of the replacement part

Identification	Description
(1)	Front wing inner panel assembly

5. Identification of replacement parts

5.1. Composition : Front wing inner panel assembly

Identification	Description	Thickness	Nature/classification
(1)	Front wing inner panel assembly	-	-
(1a)	Front wing upper mounting	1,3 mm	High strength (HSS)
(1b)	Wiper outer support	1,75 mm	High strength (HSS)
(1c)	Front wing upper rear bracket	1,5 mm	High strength (HSS)
(1d)	Fascia side support	2,50 mm	High strength (HSS)
(1e)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(1f)	Bonnet joint support	0,95 mm	Very high strength (VHSS)
(1g)	Front wing lower front bracket	2,5 mm	High strength (HSS)
(1h)	Front wing front mounting	1,5 mm	High strength (HSS)

CAUTION : Take into account the difference in thickness of the part when setting the welding station.

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 lower part	0,80 mm	High strength (HSS)
(4)	Upper bulkhead	0,95 mm	Mild steel
(5)	Windscreen lower cross member	0,95 mm	High strength (HSS)
(6)	Windscreen pillar inner panel	1,3 mm	Ultra high strength (UHSS)
(7)	Front pillar lower stiffener	1,75 mm	Ultra high strength (UHSS)
(8)	Inner sill front part	1,35 mm	Very high strength (VHSS)
(9)	Wheel arch top connection	1,45 mm	High strength (HSS)
(10)	Front suspension support	2,8 mm	Very high strength (VHSS)
(11)	Front wheel arch	1,10 mm	Very high strength (VHSS)
(12)	Front wheel arch - front part	0,95 mm	High strength (HSS)
(13)	Front wheel arch closing panel	1,25 mm	Very high strength (VHSS)

6. Preparation of the replacement part

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.

7. Cutting of the part on the body

Cut out the spot welds .

Detach the front wing inner panel assembly at the beads of structural adhesive ; Using a hot air gun.

Remove the front inner wing panel assembly .

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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The front wing inner panel assembly
• The components for adjusting

Check :

• The fits and clearances
• The position, using one of the approved measuring 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 plug welds.

Grind the MAG plug welds.

N.B. : The remaining spot welds will be applied when welding the following components : The front pillar strengthener assembly - The passenger compartment side front part - The front pillar upper gusset - The body side front reinforcement.

11. Sealing protection

Apply :

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

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 ).