Peugeot 308: Replacement : Partial rear wing

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be disconnected electrical supply.

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).

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the precautions to be taken for the pyrotechnic components .

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
	[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 .

Disconnect the ancillaries battery.

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 door
• The rear door aperture seal
• The rear bumper
• The fuel flap (depending on the side having the replacement)
• The rear bumper
• The rear lamp
• The interior trims
• The body sill plugs

Release the electrical harnesses.

Replace :

• The rear quarter panel inner panel rear expanding insert
• The rear lamp housing expanding insert (upper part)
• The rear wing inner panel expanding insert (upper part)
• The rear lamp housing expanding insert
• The rear quarter panel inner panel front expanding insert
• The rear pillar expanding insert

4. Location of the replacement part

Identification	Description
(1)	Partial rear wing

5. Identification of the replacement part

5.1. Composition : Rear wing assembly

Identification	Description	Thickness	Nature/classification
(1)	Rear wing assembly	-	-
(1a)	Rear wing	0,64 mm	Mild steel
(1b)	Tailgate strut fixing strengthener	1,45 mm	High strength (HSS)
(1c)	Tailgate aperture drip moulding	0,65 mm	Mild steel
(1d)	Rear lamp housing expanding insert	-	-
(1e)	Rear lamp housing expanding insert	-	-
(1f)	Rear lamp housing expanding insert	-	-
(1g)	Rear light housing closing	0.65 mm	Mild steel
(1h)	Rear lamp housing	1,25 mm	Mild steel
(1j)	Rear wing lower closing panel	0,65 mm	Mild steel
(1k)	Rear door striker fixing strengthener	1,15 mm	High strength (HSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Rear wing inner panel top part	0,95 mm	Mild steel
(3)	Quarter panel inner panel	0,65 mm	Mild steel
(4)	Rear wing drip moulding gusset	1,30 mm	Mild steel
(5)	Rear panel	0,65 mm	Mild steel
(6)	Tailgate drip moulding inner panel	0,65 mm	Mild steel
(7)	Rear pillar lower gusset	0,97 mm	High strength (HSS)
(8)	Tailgate drip moulding upper inner panel	1,47 mm	Mild steel
(9)	Rear wing inner panel rear part	0,64 mm	Mild steel
10)	Load floor extension	0,80 mm	High strength (HSS)
(11)	Side member rear strengthener	0,95 mm	Very high strength (VHSS)
(12)	Sill web	0,95 mm	Ultra high strength (UHSS)
(13)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(14)	Lower quarter panel inner panel	0,95 mm	Mild steel
(15)	’C’ post stiffener	0,95 mm	High strength (HSS)
(16)	Rear wing inner panel front part	0,64 mm	Mild steel

6. Replacement part preparation

CAUTION : When cleaning the mating edges, use scouring wheels only to avoid damaging the anticorrosion protection.

Cut out the spot welds .

Mark (at "a", "b" ) in the cutting zones "A", "B" ,"C", then cut .

N.B. : The cutting lines "a", "b" are shown as an indication only and may change depending on the different cases of replacement of the partial rear wing.

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

Mark (at "c", "d" ) in the cutting zones "D", "E" ,"F", then cut .

N.B. : The cutting lines "c", "d" are shown as an indication only and may change depending on the different cases of replacement of the partial rear wing.

Cut out the spot welds .

Cut out the spot welds .

Detach the partial rear wing at the expanding inserts ; Using a hot air gun.

Remove the partial rear wing.

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 setting adhesive (index "A1").

Clip the rear door striker fixing strengthener structural insert.

Seal the structural insert (17).

Seal the expanding inserts (18), (19), (20), (21), (22), (23) .

9. Adjustment

Position :

• The partial rear wing
• The components for adjusting

Check the fits and clearances .

Adjust the cuts (if necessary).

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 (at "e")
• With electric spot welds

Grind the MAG plug welds.

Weld with MAG plug welds.

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 .

Restore the voltage supply to the vehicle.

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

Reconnect the ancillaries battery.