Acura RL (1996-2004 year). Manual — part 14
• Replace the lower stiffener if necessary.
5. Set the new lower stiffener and repair part.
• Sand off the undercoat from both sides of the welded
flange on the lower stiffener and repair part.
• Clamp the new lower stiffener and repair part.
NOTE: Apply the spot sealer to the welding surface when
spot welding.
• Check the body dimensions (see
).
• Temporarily install the door, and check the door
hinge mounting position.
• Remove the repair part and MIG weld the lower
stiffener.
4. Mold the related parts.
• Fill any holed areas by MIG or gas welding.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Level and finish burrs at welded areas with a disc
sander, then even them out with a hammer and
dolly.
• Sand off the undercoat from both sides of the flange
to be welded.
NOTE: Check the damage of the honeycomb floors and if
necessary replace it (see page
).
6. Tack weld the repair part.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Remove the vise-grips and install the fender and
doors. Check for differences in level and clearance.
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Side Sill (Outer Panel)
Replacement (cont'd)
7. Perform main welding.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Weld the side sill and rear side outer joints with a MIG
welder.
• Spot weld the side sill flanges.
• Make 20% to 30% more spot welds than there were
holes drilled.
• Make 5 mm (0.2 in) holes in the MIG weld holes with
the repair part, and weld the center pillar stiffener and
wheel arch extension with a MIG welder.
• Level the weld beads at the front and rear with a disc
sander. Hammer down the projections, then fill with
solder or putty to finish.
8. Apply the sealer.
Apply sealer to the mating surfaces of the floor and
).
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, and apply an anti-rust agent
to the inside of the side sill and center pillar (see
).
11. Install the related parts.
• Install in the reverse order of removal.
• Check the door for proper installation and level
differences from the fenders.
12. Clean and check.
Clean the passenger compartment and check for water
leaks.
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Roof Panel
Description
Deformation of the roof panel is highly noticable in terms of the vehicle's outer appearance.
Before replacing the roof rail, make sure that the body is horizontal. Before welding the roof panel, adjust the roof rail flanges so
that they contact the roof panel.
Mass Production Body Welding Diagram
NOTE: When replacing the outer panel, drill holes at the
area joined to the roof side rail and rear inner panel as
shown.
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Roof Panel
Replacement
1. Remove the related parts.
Windshield
Rear window
Sunvisor
Ceiling lights
Headliner
Moonroof frame (For some types)
2. Pull out and straighten the damaged area to approxi-
mately the original shape.
NOTE: Check the inner front pillar and the inner center
pillar for position and damage.
Cut the roof panel and pull out the pillars if necessary.
• Pull out the damaged area with the frame straight-
ener before removing the roof panel.
• Attach the car to the frame straightener by tighten-
ing the underbody clamps located at the horizontal
pinch welds.
3. Keep the body level.
NOTE: Refer to the 96 Acura 3.5RL Service Manual for
safety stand location points.
Jack-up the body at the front and back. Place safety
stands at the four designated places of the side sills.
NOTE: Make sure that the right and left pillars are
parallel with the windshield surface. Check the door for
proper opening and closing.
4. Cut off the shaded areas of the roof panel.
• Cut the roof rail weld flange with a handsaw at the
four corners.
• Using a chisel, pry off the roof panel along the bold
lines as shown.
• Center punch around the spot weld imprints of the
roof gutter welded flange.
• Drill holes using the spot cutter.
• Using a chisel, pry off the welded flange.
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