Peugeot 308: Replacement : Rear wheel arch 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

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 bumper
• The tailgate
• The rear lamp
• The rear seats
• The interior trims
• The boot carpet
• The rear suspension
• The fuel flap (Depending on the side on which the work is carried out)

Release the electrical harnesses.

Replace :

• The partial rear wing
• The rear floor / rear wheelarch connection
• The rear inner wing panel front part
• The rear wing panel rear section
• The rear wing inner panel upper part
• The rear wing strengthener bulkhead
• The rear wing expanding insert (upper part)
• The rear quarter panel inner panel front expanding insert
• The rear pillar expanding insert

4. Location of the replacement part

Identification	Description
(1)	Rear wheel arch assembly

5. Identification of the replacement part

5.1. Composition : Rear wheel arch assembly

Identification	Description	Thickness	Nature/classification
(1)	Rear wheel arch assembly	-	-
(1a)	Rear back rest striker fixing plate	1,45 mm	High strength (HSS)
(1b)	Rear seat belt return fixing strengthener	1,30 mm	High strength (HSS)
(1c)	Load floor support	1,30 mm	High strength (HSS)
(1d)	Rear wheel arch	0,80 mm	Mild steel
(1e)	Rear suspension support	2,00 mm	High strength (HSS)
(1f)	Rear suspension	1,00 mm	High strength (HSS)
(1g)	Rear wheelarch strengthener	1,40 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)	Rear lower side member	1,70 mm	Very high strength (VHSS)
(3)	Lower quarter panel inner panel	1,20 mm	Very high strength (VHSS)
(4)	Quarter panel inner panel	0,65 mm	Mild steel
(5)	Load floor extension	0,80 mm	High strength (HSS)
(6)	Front upper side member	1,60 mm	Ultra high strength (UHSS)

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.

Mark then drill to a diameter of 7 mm (at "a") the electric spot weld over 2 thicknesses 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 .

Cut :

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

Cut out the spot welds .

Remove the bolt (at "c").

Separate the rear wheel arch assembly at the beads of structural adhesive;Using a heat gun .

Remove the rear 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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The rear wheel arch 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 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 "d")

Grind the MAG plug welds.

Weld with electric spot welds.

Refit the bolt (at "e").

11. Sealing protection

Apply :

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

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.