Peugeot 308: Replacement : Front right floor

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.

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.

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 :

• Rear strengthener for front floor
• 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

5. Identification of replacement parts

5.1. Composition : Front floor

Identification	Description	Thickness	Nature/classification
(1)	Front floor	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
(2)	Outer chassis leg	1,75 mm	Ultra high strength (UHSS)
(3)	Inner sill	1,35 mm	Very high strength (VHSS)
(4)	Rear chassis leg	1,30 mm	Very high strength (VHSS)
(5)	Heel panel	0,67 mm	Very high strength (VHSS)
(6)	Heel floor inner panel	1,27 mm	High strength (HSS)
(7)	Tunnel	1,35 mm	Very high strength (VHSS)
(8)	Interior chassis member	1,75 mm	Ultra high strength (UHSS)
(9)	Tunnel front strengthener	1,25 mm	Very high strength (VHSS)
(10)	Lower bulkhead	1,15 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.

7. Cutting of the part on the body

Cut out the spot welds .

Cut out the spot welds on 2 thicknesses.

Level off the laser welds .

Level off the MIG weld beads.

Remove the front floor .

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.

9. Adjustment

Position :

• The front floor panel
• 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.

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

Weld by means of MAG plug welds in 3 thicknesses.

Grind the MAG plug welds.

Weld with MAG plug welds.

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 .

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• 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 .

Reconnect the ancillaries battery.