Acura TL (1995-1998) body repair. Manual — part 11
Replacement
1. Remove the related parts.
• Front seat
• Carpet
• Refer to the front side frame (see page
).
2. Pull out and straighten the damaged area.
• The front side outrigger receives impact through the
front side frame or side sill. Such impact generally
requires replacement of all these parts.
• Before cutting off the front side outrigger or side sill,
pull out the damaged area with the frame straight-
ener and correct the related parts such as the front
floor and dashboard. Check the clearance and level
differences of the front doors.
• Jack up the body and place safety stands at the four
designated places of the side sills. If necessary,
place safety stands at the rear of the frame.
3. Peel off the undercoat.
Heat the undercoat at the weld areas of the front side
outrigger and side frame with a gas torch and peel off the
undercoat with a metal spatula.
CAUTION: Be careful not to burn the fittings inside
the passenger compartment when heating.
4. Remove the front side outrigger.
• Center punch around the spot weld imprints on the
front side outrigger from inside the passenger com-
partment.
• Drill holes is the spot welded areas with a 5 mm (0.2
in) drill.
• Remove the MIG welds with a disc sander.
NOTE: Drill holes through the parts completely since the
replacement front side outrigger will be welded by MIG
welding.
• Center punch around the spot weld imprints on the
front side frame, floor frame and inside sill.
• Drill holes using a spot cutter.
NOTE: When drilling holes be careful not to drill down to
the front side frame, floor frame and inside sill.
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Front Side Outrigger/Front Side Extension
Replacement (cont'd)
3.2TL:
FRONT SIDE
FRAME
FRONT SIDE
EXTENSION
FLOOR FRAME
Level off and finish the burrs of the pried off spot
welds with a disc sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
5. Mold the related parts.
Reshape the lower dashboard, front side frame, front
floor, inside sill and side sill inner joint using a hammer
and dolly.
2.5TL:
Remove the remains of
the front side outrigger.
FRONT SIDE FRAME
6. Set the new front side outrigger.
• Remove the undercoat from both sides of the areas
to be spot welded with a sander to expose the steel
plate.
• Clamp the weld flanges with the side sill using the
vise-grip pliers. Set the front side outrigger on the
side frame using a jack.
• Drill 3 mm (0.12 in) holes, and screw 5 mm self-
tapping screws into the drilled holes at the areas
where the front side outrigger does not fit closely.
• Even out the welded flange and damaged area with
a hammer and dolly.
7. Perform the main welding.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• From the passenger compartment side, weld the
holes in the lower dashboard, front floor and floor
frame with a MIG welder.
• Weld the front side frame and front side outrigger
using MIG welds.
2.5TL:
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Make 5 mm (0.2 in) holes in the MIG weld holes with
the outrigger or front side extension, and weld the
front side frame, floor frame and inside sill with a MIG
welder.
2.5TL:
6 point of MIG welding the bending angle of a flange.
Welding pitch=30 mm (1.2 in)
3.2TL:
).
Apply sealer to the mating surface of the lower dash-
board and front floor.
9. Apply the paint.
See Paint Repair section.
• Ventilate when spraying paint. Most paint
contains substances that are harmful if inhaled
or swallowed. Read the paint label before
opening the paint container.
• Avoid contact with skin. Wear an approved
respirator, gloves, eye protection and appropriate
clothing when painting.
• Paint is flammable. Store it in a safe place, and
keep it away from sparks, flames or cigarettes.
10. Apply the undercoat.
Undercoat the front floor, etc, and apply anti-rust agent
to the inside of the front side outrigger and side sill (see
).
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Front Pillar (Outer Panel)
Description
The front pillar is connected to the roof, windshield, the door hinges, and side sills and is a highly important support. Connection
of the front pillar determines the position of the windshield and front door. Align the front fender, door, and windshield while
the front pillar is loosely mounted, and check the clearances and level differences.
Mass Production Body Welding Diagram
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