Peugeot 308: Replacement : Rear door panel

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 .

1. Information

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
	[1130]	Door panel crimping tools

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 rear door.

Strip the rear door.

4. Location of the replacement part

Identification	Description
(1)	Rear door panel
(2)	Damping pad(index "H5") (160 mm x 160 mm)

5. Identification of the replacement part

Identification	Description	Thickness	Nature/classification
(1)	Rear door panel	0,65 mm	High strength (HSS)

6. Preparation of the replacement part

"A" = 199 mm.

"B" = 443 mm.

"C" = 452 mm.

Fit the sound deadening pads (2) on the door panel (1) (index "H5").

7. Cutting out

Cut out the rear door panel.

Separate the rear door panel.

Remove the rear door panel.

8. Cleaning and preparation of the door

Prepare the mating edges .

Apply a structural adhesive index "B8".

Apply a filling adhesive (index "A1").

9. Adjustment

Fit the rear door panel.

Check the fit.

10. Crimping

Crimp the rear door panel ; Using crimping tools [1130].

11. Sealing protection

Apply a sealing mastic (index "A1") :

• To the lower section of the rear door panel
• To the side section of the rear door panel

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

12. Additional operations

ESSENTIAL : Reactivate the pyrotechnic systems .

Assemble the rear door.

Refit the rear door.

13. Reinitialisation

CAUTION : Perform the operations that are required after reconnecting the ancillaries battery .

Restore the voltage supply to the vehicle.

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.