Peugeot 308: Replacement : Passenger compartment side assembly

Peugeot 308 2021-2025 (P5) Service Manual / Bodywork :: Side section / Side panel / Replacement : Passenger compartment side assembly

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 : 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 .

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 .

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 front wing
The front door
The rear door
The front and rear door aperture seals
The interior trims
The rear bumper
The body sill plugs
The windscreen
The tailgate
The panoramic sunroof (depending on equipment)

Release the electrical harnesses.

Replace :

The roof
The rear panel
The passenger compartment side front closing panel expanding insert
The windscreen pillar expanding insert
The rear quarter panel inner panel front expanding insert
The rear quarter panel inner panel rear expanding insert
The rear pillar expanding insert
The centre pillar exterior expanding insert
The tailgate strut fixing strengthener structural insert

4. Location of the replacement part

Identification	Description
(1)	Passenger compartment side assembly

5. Identification of the replacement part

5.1. Composition : Passenger compartment side assembly

Identification	Description	Thickness	Nature/classification
(1)	Passenger compartment side assembly	-	-
(1a)	Passenger compartment side panel	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 lamps housing upper expanding insert	-	-
(1e)	Rear lamps housing expanding insert	-	-
(1f)	Rear lamp housing closer	0,65 mm	Mild steel
(1g)	Rear lamp housing	0,65 mm	Mild steel
(1h)	Rear wing lower closing panel	0,65 mm	Mild steel
(1j)	Rear door striker fixing strengthener	1,15 mm	High strength (HSS)
(1k)	Front wing intermediate rear support	1,45 mm	High strength (HSS)
(1l)	Front wing upper rear bracket	1,45 mm	High strength (HSS)
(1m)	Windscreen trim support	0,50 mm	Very high strength (VHSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Windscreen pillar strengthener	1,10 mm	Ultra high strength (UHSS)
(3)	Roof arch inner panel	1,15 mm	Very high strength (VHSS)
(4)	Roof bow strengthener	1,10 mm	Ultra high strength (UHSS)
(5)	Upper quarter panel inner panel	0,65 mm	Mild steel
(6)	Roof rear crossmember	0,77 mm	High strength (HSS)
(7)	Rear wing inner panel top part	0,95 mm	Mild steel
(8)	Quarter panel inner panel	0,65 mm	Mild steel
(9)	Rear wing drip moulding gusset	1,30 mm	Mild steel
(10)	Tailgate drip moulding inner panel	0,65 mm	Mild steel
(11)	Rear pillar lower gusset	0,97 mm	High strength (HSS)
(12)	Load floor extension	0,80 mm	High strength (HSS)
(13)	Tailgate drip moulding lower inner panel	1,47 mm	Mild steel
(14)	Rear wing inner panel rear part	0,64 mm	Mild steel
(15)	Centre pillar strengthener (upper part)	1,70 mm	Ultra high strength (UHSS)
(16)	Centre pillar strengthener (lower section)	1,90 mm	Very high strength (VHSS)
(17)	Side member rear strengthener	0,95 mm	Very high strength (VHSS)
(18)	Sill web	0,95 mm	Ultra high strength (UHSS)
(19)	Inner sill	1,25 mm	Very high strength (VHSS)
(20)	Front interior sill	1,35 mm	Ultra high strength (UHSS)
(21)	Front pillar strengthener	1,25 mm	Ultra high strength (UHSS)
(22)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(23)	Windscreen pillar inner panel	1,30 mm	Ultra high strength (UHSS)
(24)	Centre pillar inner panel	0,65 mm	High strength (HSS)
(25)	Lower quarter panel inner panel	0,95 mm	Mild steel
(26)	Rear pillar strengthener	0,95 mm	High strength (HSS)
(27)	Rear wing inner panel front part	0,85 mm	Mild steel
(28)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(29)	Reel fixing bracket (front section)	1,30 mm	High strength (HSS)
(30)	Front pillar upper gusset	1,20 mm	High strength (HSS)

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.

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 .

Detach the passenger compartment side assembly at the expanding inserts ; Using a hot air gun.

Remove the passenger compartment side 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 setting adhesive (index "A1").

Clip the structural insert (31).

Seal the structural insert (31).

Seal the expanding inserts (32), (33), (34), (35), (37), (38), (39).

Seal the structural insert (36).

9. Adjustment

Position :

The passenger compartment side assembly
The components for adjusting

Check the fits and clearances .

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.