Peugeot 308: Replacement : Roof panel

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
	[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 .

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 windscreen
• The headlining
• The interior trims
• The tailgate
• The tailgate hinges
• The aerial wire
• The aerial base

Release the electrical harnesses.

4. Location of the replacement part

Identification	Description
(1)	Roof panel

5. Identification of the replacement part

5.1. Composition : Roof panel

Identification	Description	Thickness	Nature/classification
(1)	Roof panel	0,64 mm	Mild steel

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Roof front crossmember	0,90 mm	Mild steel
(3)	Central roof bow	1,10 mm	Very high strength (VHSS)
(4)	Roof rear crossmember	0.77 mm	High strength (HSS)
(5)	Rear wing drip moulding gusset	1,05 mm	Mild steel
(6)	Tailgate aperture drip moulding	0,65 mm	Mild steel
(7)	Passenger compartment side panel	0,65 mm	Mild steel
(8)	Windscreen pillar inner panel	1,10 mm	Very high strength (VHSS)
(9)	Roof front crossmember bracket	1,45 mm	Very high strength (VHSS)

6. Replacement part preparation

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.

Sand the mating edges with fine grain abrasive paper.

Position masking tape on the edges of the roof (at "a").

7. Cutting of the part on the body

"A" = 5 mm.

Mark (at "b") to the dimension "A", then cut ; Using the electric knife [FEIN-400E].

CAUTION : Do not damage the parts located under the roof when cutting.

Cut out the spot welds .

Cut out the spot welds .

Detach the roof at the beads of structural adhesive ; Using a hot air gun.

Remove the roof panel.

Level the remainder of the roof ; With the aid of a grinder.

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 masking tape to the edges of the passenger compartment sides (at "c").

Prepare the mating edges .

Apply a setting adhesive (index "A1").

Thoroughly degrease the entire roof edge ; Using a cleaner index "J1".

Apply structural adhesive (index "B12") (at "d").

Correctly degrease the meeting edges of the roof and the passenger compartment sides ; Using a cleaner index "J1".

Apply structural adhesive (index "B12") (at "e").

9. Adjustment

N.B. : 2 operators are required for this operation.

Position :

• The roof
• The components for adjusting

Check the fits and clearances .

Clamp the part into position.

Check the condition of the beads of structural adhesive.

Perform the following operations (if necessary) :

• Add structural adhesive (index "B12") (at "f")
• Smooth the excess structural adhesive (at "f")
• Sand the strip of structural adhesive after drying

Remove the masking tape from the roof and the passenger compartment sides.

CAUTION : Leave the structural adhesive to dry for 2 days at room temperature or 2 hours at 60°C.

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 electric spot welds
• By means of MAG plug welds (at "g")

Grind the MAG plug welds.

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 .

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.