Peugeot 308: Replacement : Front left floor

Peugeot 308 2021-2025 (P5) Service Manual / Bodywork :: Front section / Front floor / Replacement : Front left floor

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 .

ESSENTIAL : For any paint retouching operation on a vehicle that has the STOP and START system requiring a paint booth, it is necessary to remove the central voltage retention device assembly (DMTC) if the temperature exceeds 80°C.

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

In after sales repair, the laser weld beads are replaced with electric spot welds or plug welds ; Observe the following standards :

Laser weld bead of 30 mm = 1 electric spot weld or plug weld
Laser weld bead of 70 mm = 2 electric spot welds or plug welds

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 .

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 dashboard
The centre console
The front seat
The rear seat
The floor carpet (partly)
The protectors under the body

Release the electrical harnesses.

Replace the front seat rear crossmember (Only if replacing the front floor, central and rear section).

Replace (If replacing the complete front left-hand floor) :

The front floor rear stiffener
The front seat front crossmember
The front seat rear crossmember
The chassis leg stiffener, rear section
The chassis leg/sill link
The front subframe rear fixing support
The inner sill assembly
The rear inner sill
The sill strengthener
The outer sill

4. Location of the replacement part

Identification	Description
(1)	Front floor, central section
(2)	Front floor closing
(3)	Front floor, rear section
(4)	Front floor, front section

5. Identification of replacement parts

5.1. Composition : Front left floor

Identification	Description	Thickness	Nature/classification
(1)	Front floor, central section	1,30 mm	Very high strength (VHSS)
(2)	Front floor closing	2,00 mm	Very high strength (VHSS)
(3)	Front floor, rear section	0,75 mm	High strength (HSS)
(4)	Front floor, front section	0,75 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
(5)	Tunnel LH front stiffener	1,25 mm	Very high strength (VHSS)
(6)	Tunnel	1,35 mm	Very high strength (VHSS)
(7)	Heel panel	0,65 mm	Very high strength (VHSS)
(8)	Left-hand side chassis leg	1,30 mm	High strength (HSS)
(9)	Inner sill	1,25 mm	Very high strength (VHSS)
(10)	Front interior sill	1,35 mm	Very high strength (VHSS)
(11)	Lower bulkhead	1,15 mm	High strength (HSS)
(12)	Front subframe rear fixing mounting	2,50 mm	Very high strength (VHSS)
(13)	Interior chassis member	1,76 mm	Ultra high strength (UHSS)
(14)	Heel floor inner panel	1,25 mm	High strength (HSS)
(15)	Left-hand side chassis leg link	2,50 mm	Very high strength (VHSS)
(16)	Left outer chassis leg	1,75 mm	Ultra high strength (UHSS)
(17)	Chassis leg/sill link	1,15 mm	Very high strength (VHSS)
(18)	Interior chassis member	1,75 mm	Ultra high strength (UHSS)
(19)	Rear chassis leg rear section	1,30 mm	Very high strength (VHSS)

6. Replacement part preparation

6.1. Front floor, central section

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.

6.2. Front floor closing

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.

6.3. Front floor, rear section

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.

6.4. Front floor, front section

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.

7. Cutting of the part on the body

7.1. Front floor, central section

Cut out the spot welds .

Remove the front floor, central section.

7.2. Front floor closing

Cut out the spot welds .

Remove the front floor closing panel.

7.3. Front floor, rear section

N.B. : Before removing the front floor, rear section, it is necessary to remove the front floor closing panel.

Cut :

The spot welds
The spot welds over 2 thicknesses (at "a" and "b")

Remove the front floor, rear section.

7.4. Front floor, front section

N.B. : Before removing the front floor, front section, remove the front floor, central section, and the front floor closing panel.

Cut :

The spot welds
The spot welds over 2 thicknesses (In "c")

Level off the MIG weld beads.

Remove the front floor, front section.

8. Cleaning and preparation of the body

8.1. Front floor, front section

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.

8.2. Front floor, rear section

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.

8.3. Front floor, central section

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.

9. Adjustment

Position :

The front floor, front section
The front floor, rear section
The front floor closing panel
The front floor, central section
The components for adjusting

Check the position using one of the approved measurement systems.

Support the parts in 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.

10.1. Front floor, front section

Weld :

With MAG plug welds
By means of MAG plug welds in 2 thicknesses (In "d")

Grind the MAG plug welds.

Weld using MIG weld beads.

N.B. : The remaining spot welds or weld beads will be applied when welding the following components : The chassis leg stiffener, rear section - The front seat front crossmember - The front seat rear crossmember - The front subframe rear fixing support - The chassis leg/sill link - The inner sill assembly - The rear inner sill .

10.2. Front floor, rear section