Peugeot 308: Replacement : Heel panel assembly

Peugeot 308 2021-2025 (P5) Service Manual / Bodywork :: Rear section / Rear floor / Replacement : Heel panel assembly

ESSENTIAL : Before any operation on the structure of a vehicle fitted with a traction battery, the vehicle must be isolated by an authorised technician.

ESSENTIAL : Observe the safety and cleanliness recommendations .

ESSENTIAL : Observe the precautions to be taken for the pyrotechnic components .

ESSENTIAL : Any repair work carried out on a vehicle with on board electric energy (electric vehicle/hybrid vehicle) must be carried out by an authorised person.

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
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 before disconnecting the ancillaries batteries .

Disconnect the ancillaries batteries (Following the specific procedure ).

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 rear bench seat
The interior trims
The floor carpets
The fuel tank

Release the electrical harnesses.

4. Location of the replacement part

Marking	Description
(1)	Heel panel assembly

5. Identification of the replacement part

5.1. Composition : Heel panel assembly

Marking	Description	Thickness	Nature/classification
(1)	Heel panel assembly	-	-
(1a)	Heel floor inner panel(side parts)	1,25 mm	Very high strength (VHSS)
(1b)	Tunnel heel panel connection	1,25 mm	Very high strength (VHSS)
(1c)	Heel floor stiffener	1,15 mm	High strength (HSS)
(1d)	Heel floor inner panel(central section)	1,25 mm	High strength (HSS)
(1e)	Heel panel(side parts)	1,15 mm	Very high strength (VHSS)
(1f)	Heel plate strengthener	1,15 mm	Very high strength (VHSS)
(1g)	Heel panel	0,65 mm	Very high strength (VHSS)

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

Marking	Description	Thickness	Nature/classification
(2)	Tunnel	1,35 mm	Very high strength (VHSS)
(3)	Heel plate crossmember	0,85 mm	Very high strength (VHSS)
(4)	Rear floor	0,95 mm	Very high strength (VHSS)
(5)	Front upper side member	1,45 mm	Ultra high strength (UHSS)
(6)	Rear interior sill	1,35 mm	Very high strength (VHSS)
(7)	Interior heel floor - sill coupling	1,75 mm	High strength (HSS)
(8)	Rear chassis leg	1,30 mm	Very high strength (VHSS)
(9)	Tunnel strengthener	1,35 mm	Ultra high strength (UHSS)
(10)	Front floor	0,75 mm	Very high strength (VHSS)

6. Preparation of the replacement part

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.

Mark then drill to a diameter of 7 mm (at "a") the electric spot weld over 2 thicknesses 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.

7. Cutting of the part on the body

Cut :

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

Cut :

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

Cut :

The spot welds
The spot welds over 2 thicknesses(at "d")

Cut :

The spot welds
The spot welds over 2 thicknesses(at "e")

Detach the heel panel assembly ; Using the hot air blower.

Remove the heel panel 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 heel panel 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.