Peugeot 308: Replacement : Inner sill 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. Tools

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 windscreen
• The front wing
• The front door
• The rear door
• The front seat

Release the electrical harnesses.

Replace :

• The front pillar exterior expanding insert
• The sill front closer expanding insert
• The inner sill expanding insert
• The passenger compartment side
• The front pillar strengthener
• The sill strengthener assembly
• The centre pillar strengthener
• The inner sill assembly (rear section)

4. Location of the replacement part

Identification	Description
(1)	Inner sill assembly

5. Identification of replacement parts

5.1. Composition : Inner sill assembly

Identification	Description	Thickness	Nature/classification
(1)	Inner sill assembly	-	-
(1a)	Front interior sill	1,35 mm	Very high strength (VHSS)
(1b)	Inner sill	1,25 mm	Very high strength (VHSS)
(1c)	Centre pillar lower partition	1,45 mm	Very high strength (VHSS)
(1d)	Sill front partition	1,45 mm	Very high strength (VHSS)
(1e)	Front pillar lower stiffener	1,75 mm	Ultra high strength (UHSS)

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Lower bulkhead	1,15 mm	High strength (HSS)
(3)	Lateral bulkhead cross member	1,75 mm	Ultra high strength (UHSS)
(4)	Front seat front cross member	1,15 mm	Very high strength (VHSS)
(5)	Front seat rear crossmember	0,65 mm	Ultra high strength (UHSS)
(6)	Rear floor strengthener	1,30 mm	High strength (HSS)
(7)	Front floor strengthener	1,30 mm	High strength (HSS)
(8)	Front floor	0,75 mm	Very high strength (VHSS)
(9)	Chassis leg/sill link	1,15 mm	Very high strength (VHSS)
(10)	Front wing inner panel	0,95 mm	Very high strength (VHSS)
(11)	Front floor right side lateral stiffener	1,90 mm	Ultra high strength (UHSS)

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.

Clip in the expanding insert (12) .

7. Cutting of the part on the body

Cut :

• The spot welds
• The spot welds in 2 thicknesses (at "a")

Cut out the spot welds .

Cut :

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

Cut :

• The spot welds
• The spot welds in 2 thicknesses (at "c")

Detach the inner sill assembly ; Using the hot air blower.

Remove the inner sill 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 inner sill 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 electric spot welds
• By means of MAG plug welds (at "d")
• By means of MAG plug welds in 2 thicknesses (at "e")

Grind the MAG plug welds.

Weld with MAG plug welds.

Grind the MAG plug welds.

Weld :

• By MAG plug welds in 2 thicknesses (at "f")
• With electric spot welds

Weld :

• By means of MAG plug welds
• By means of MAG plug welds in 2 thicknesses (at "h")

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 .

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.