Peugeot 308: Replacement : Front left seat front and rear crossmembers

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

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 : Remove or protect the components that are in the repair area and that can be damaged by heat or dust.

Remove :

• The centre console
• The front seat
• The carpet (partly)
• The interior trims
• The traction battery
• The centre pillar strengthener

Release the electrical harnesses.

4. Location of the replacement part

Identification	Description
(1)	Front left seat rear crossmember

5. Identification of replacement parts

Identification	Description	Thickness	Nature/classification
(1)	Front left seat rear crossmember	1,70 mm	Very high strength (VHSS)

6. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Tunnel	1,35 mm	Very high strength (VHSS)
(3)	Rear strengthener for front floor	1,30 mm	Very high strength (VHSS)
(4)	Front floor, rear section	0,75 mm	High strength (HSS)
(5)	Inner sill	1,25 mm	Very high strength (VHSS)
(6)	Front left floor closing panel	2,00 mm	Very high strength (VHSS)

7. Preparation of the replacement parts

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.

8. Cutting of the parts on the body

Cut :

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

Remove the front seat front crossmember .

9. 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.

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.

10. Adjustment

Position :

• Front left seat rear crossmember
• The components for adjusting

Clamp the part into position.

11. Welding

CAUTION : Set the welding station.

Set 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 :

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

Grind the MAG plug welds.

12. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Underseal protection

Painting, then spraying of the index "C5" product into the hollow sections in the repair zone.

13. Additional operations

Refit the electrical harnesses and reinstall all removed components.

14. 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 .

Reconnect the ancillaries battery .