Peugeot 308: Replacement : Quarter panel inner panel 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 door
• The tailgate
• The tailgate hinges
• The windscreen
• The rear bench seat
• The rear bumper
• The rear bumper frame
• The rear lamps
• The interior trims

Release the electrical harnesses.

Replace :

• The roof
• The partial passenger compartment side
• The rear panel assembly
• The rear wing lower closing panel
• The rear lamp housing
• The rear lamp housing closer
• The roof bow strengthener
• The tailgate aperture drip moulding
• The rear quarter panel inner panel rear expanding insert
• The rear quarter panel inner panel expanding insert
• The rear quarter panel inner panel front expanding insert
• The rear lamp housing expanding insert (upper part)
• The rear lamp housing expanding insert
• The rear pillar expanding insert

4. Location of the replacement part

Identification	Description
(1)	Quarter panel inner panel assembly

5. Identification of the replacement part

5.1. Composition : Quarter panel inner panel assembly

Identification	Description	Thickness	Nature/classification
(1)	Quarter panel inner panel assembly	-	-
(1a)	Upper quarter panel inner panel	0,65 mm	Mild steel
(1b)	Rear seat belt reel securing bracket	1,45 mm	High strength (HSS)
(1c)	Rear wing inner panel top part	0,65 mm	High strength (HSS)
(1d)	Rear wing drip moulding gusset	1.25 mm	Mild steel
(1e)	Tailgate drip moulding inner panel	0,65 mm	Mild steel
(1f)	Tailgate drip moulding lower inner panel	1,15 mm	Mild steel
(1g)	Rear pillar inner panel lower gusset	1,27 mm	High strength (HSS)
(1h)	Tailgate pillar lower gusset	0,65 mm	Mild steel
(1j)	Rear wing inner panel rear part	0,65 mm	Mild steel
(1k)	Rear wing inner panel front part	0,85 mm	Mild steel
(1l)	Rear pillar strengthener	0,65 mm	High strength (HSS)
(1m)	Lower quarter panel inner panel	1,20 mm	Very high strength (VHSS)
(1n)	Rear seat belt return fixing strengthener	1,30 mm	High strength (HSS)
(1p)	Rear wing strengthener bulkhead	1,75 mm	Mild steel
(1q)	Quarter panel inner panel	0,65 mm	Mild steel
(1r)	Tailgate stop bracket	1,25 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)	Roof arch inner panel	1,15 mm	Very high strength (VHSS)
(3)	Rear back rest striker fixing plate	1,45 mm	High strength (HSS)
(4)	Roof rear crossmember	0,95 mm	High strength (HSS)
(5)	Rear tailgate hinge strengthener	1,90 mm	High strength (HSS)
(6)	Load floor extension	0,80 mm	High strength (HSS)
(7)	Side member rear strengthener	0,95 mm	Very high strength (VHSS)
(8)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(9)	Front upper side member	1,60 mm	Ultra high strength (UHSS)
(10)	Rear wheel arch	0,80 mm	Mild steel

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 (at "a").

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.

7. Cutting of the part on the body

Cut out the spot welds .

Cut out the spot welds .

Cut out the spot welds .

Cut out the spot welds .

Detach the rear quarter panel inner panel assembly at the beads of structural adhesive ; Using the hot air blower.

Grind away the weld beads.

Remove the quarter panel inner panel 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.

Apply a structural adhesive index "B3".

9. Adjustment

Position :

• The quarter panel inner panel 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 (at "b")
• With electric spot welds

Grind the MAG plug welds.

Weld with electric spot welds.

Weld with electric spot welds.

Weld with electric spot welds.

Weld with MAG weld bead.

N.B. : Do not grind the MAG weld beads.

N.B. : The remaining electric spot welds will be applied during the welding of the following components : The rear wing assembly - The rear panel assembly - The roof - Tailgate aperture drip moulding - Roof bow strengthener - Rear light housing closing - Tail lamp housing - Rear wing lower closing panel.

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 .

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.