Peugeot 308: Replacement : Rear panel assembly

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).

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

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

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 .

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 bumper
• The rear lamps
• The rear bumper frame
• The boot trims
• The plugs

Release the electrical harnesses.

4. Location of the replacement part

Identification	Description
(1)	Rear panel assembly

5. Identification of the replacement part

5.1. Composition : Rear panel assembly

Identification	Description	Thickness	Nature/classification
(1)	Rear panel assembly	-	-
(1a)	Rear panel	0,65 mm	Mild steel
(1b)	Rear inner panel closing plate	1,45 mm	Mild steel
(1c)	Rear panel inner panel	0,65 mm	Mild steel
(1d)	Tailgate striker fixing stiffener	1,47 mm	High strength (HSS)
(1e)	Rear inner panel closing plate	1,45 mm	Mild steel

5.2. Identification of the parts adjacent to the replacement part

Identification	Description	Thickness	Nature/classification
(2)	Load floor rear part	0,65 mm	Mild steel
(3)	Rear side member end fitting	3.00 mm	High strength (HSS)
(4)	Tailgate drip moulding lower inner panel	1,15 mm	Mild steel
(5)	Rear light housing closing	0,65 mm	Mild steel
(6)	Passenger compartment side panel	0,65 mm	Very high strength (VHSS)

CAUTION : Take into account the difference in thickness of the parts when adjusting the welding station.

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 .

Grind away the weld beads.

Detach the rear panel assembly at the beads of structural adhesive ; Using the hot air blower.

Remove the rear 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 rear panel assembly
• The components for adjusting

Check the fits and clearances .

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.

Weld with electric spot welds.

MAG plug weld.

Grind the MAG plug welds.

Weld with MAG weld bead.

Grind the MAG weld beads.

11. Sealing protection

Apply :

• A layer of etch primer to the zones exposed
• Sealing mastic (index "A1")
• 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 .

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.