Peugeot 308: Replacement : Outer sill (Body sill)

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 front wing
• The front door
• The rear door
• The front and rear door aperture seals
• The interior trims
• The body sill plugs

Release the electrical harnesses.

Replace :

• The front pillar exterior expanding insert
• The sill front closer expanding insert
• The centre pillar exterior expanding insert
• The rear pillar expanding insert

4. Location of the replacement part

Identification	Description
(1)	Outer sill (Body sill)

5. Identification of replacement parts

5.1. Composition : Outer sill (Body sill)

Identification	Description	Thickness	Nature/classification
(1)	Outer sill (Body sill)	0,64 mm	Mild steel

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Front pillar strengthener	1,25 mm	Ultra high strength (UHSS)
(3)	Centre pillar inner panel	0,65 mm	High strength (HSS)
(4)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(5)	Lower quarter panel inner panel	0,65 mm	Mild steel
(6)	Centre pillar upper strengthener	1,80 mm	Ultra high strength (UHSS)
(7)	Rear wing inner panel front part	0,85 mm	Mild steel
(8)	Rear sill strengthener	0,95 mm	Very high strength (VHSS)
(9)	Side member web strengthener	1,15 mm	Ultra high strength (UHSS)
(10)	Front interior sill	1,35 mm	Very high strength (VHSS)
(11)	Central interior sill	1,35 mm	Very high strength (VHSS)
(12)	Front seat belt reel fixing bracket	1,30 mm	High strength (HSS)

CAUTION : Take into account the difference in thickness of the parts when adjusting the welding station.

6. Preparation of the replacement parts

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

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

N.B. : The cutting lines "a", "b", "c" are shown as an indication only and may change according to the different cases of replacement of the outer sill.

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 "d", "e", "f") in the cutting zones "D", "E", "F", then cut .

N.B. : The cutting lines "d", "e", "f" are shown as an indication only and may change according to the different cases of replacement of the outer sill.

Cut out the spot welds .

Detach the outer sill at the expanding inserts ; Using a hot air gun.

Remove the exterior longeron (Body sill).

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.

Seal the expanding inserts (13), (14), (15), (16) .

Apply setting adhesive (index "A1") (at "g").

9. Adjustment

Position :

• The outer sill (Body sill)
• 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 with MAG weld bead.

Grind the MAG weld beads.

Weld with electric spot 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.