Peugeot 308: Replacement : Front upper side member

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

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 rear suspension
• The rear bench seat
• The fuel tank
• The interior trims
• The boot carpet

Release the electrical harnesses.

Replace :

• The rear suspension crossmember
• The rear wheel arch assembly
• The rear floor / rear wheelarch connection

4. Location of the replacement part

Identification	Description
(1)	Upper front side member assembly

5. Identification of replacement parts

5.1. Composition : Upper front side member assembly

Identification	Description	Thickness	Nature/classification
(1)	Upper front side member assembly	-	-
(1a)	Rear axle crossmember endpiece	1,45 mm	High strength (HSS)
(1b)	Front upper side member	1,45 mm	Ultra high strength (UHSS)
(1c)	Anti-submersion plate	1,95 mm	Mild steel

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Rear floor	0,95 mm	Very high strength (VHSS)
(3)	Rear axle crossmember closing panel	1,25 mm	Very high strength (VHSS)
(4)	Load floor	0,67 mm	Mild steel
(5)	Rear upper side member	1,35 mm	Ultra high strength (UHSS)
(6)	Rear lower side member	1,65 mm	Very high strength (VHSS)
(7)	Rear wheel arch	0,80 mm	Mild steel
(8)	rear suspension mounting	2,20 mm	Very high strength (VHSS)
(9)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(10)	Heel panel(side parts)	1,15 mm	Very high strength (VHSS)
(11)	Heel panel	0,65 mm	Very high strength (VHSS)
(12)	Rear axle support strengthener	2,20 mm	High strength (HSS)
(13)	Side rail - side member connection	2,20 mm	Very high strength (VHSS)
(14)	Rear heel mounting	2,50 mm	Very high strength (VHSS)
(15)	Front lower side member	2,50 mm	High strength (HSS)

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.

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 :

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

Detach the upper front side member assembly ; Using a hot air gun.

Remove the upper front side member 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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The upper front side member assembly
• 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.

Weld :

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

Grind the MAG plug welds.

11. Sealing protection

Apply :

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