Acura RL (1996-2004 year). Manual — part 11
• Remove the burrs from the drilled sections with a
disc sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
• Center punch around the spot weld imprints on the front
side frame and front side extension from inside the
passenger compartment.
• Drill holes in the spot welded area with a 5 mm (0.2 in)
drill.
NOTE: Drill holes completely through the parts since the
replacement front side frame and front side extension will be
welded by MIG welding.
• Remove the MIG welds of the front side frame-and-lower
dashboard with a disc sander.
NOTE: When drilling holes ( , and ) be careful not
to drill down to the inside sill.
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Front Side Frame
Replacement (cont'd)
6. Mold the related parts.
• Reshape the front wheelhouse and damper housing
lower dashboard-to-front floor joint using a hammer
and dolly.
• Fill all drilled holes by MIG or gas welding.
NOTE: Use of a positioning jig is recommended (see
).
• Clamp the front bulkhead and front wheelhouse/
damper housing with squill vises and vise-grips.
• Measure the front compartment diagonally.
• Spot weld several points in the clamped sections,
and temporarily attach the front side frame.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Check the body dimensions (see
).
8. Perform the main welding.
• Make 20% to 30% more spot welds than there were
holes drilled.
• Weld as much as possible with the jig still mounted.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Weld the front side frame, wheelhouse, damper
housing and bulkhead.
7. Set the new front side frame.
• Remove the undercoat from the both sides of the
welding section, and expose the steel plate using a
disc sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Tighten the front side frame against the front floor
and side sill using vise-grips or pliers.
• Place a jack under the front side frame end and
support it, and measure the positions for temporary
attachment.
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• and make 5 mm (0.2 in) holes in the MIG weld
holes with the front side extension, and plug weld the
inside sill, floor frame and side sill extension with a MIG
welder.
9. Finish the welds.
Use a hammer and dolly to even out the damper housing,
wheelhouse, lower dashboard, front bulkhead and side
sill flanges for a close fit with the surface of the front side
frame.
).
Apply sealer to the mating surfaces of the lower dash-
board, etc.
11. 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.
12. Apply the undercoat.
Undercoat the front floor, and apply anti-rust agent to
the inside of the welding section of the side sill, front side
frame, etc (see
).
13. Install the related parts.
Install in the reverse order in which they were removed.
14. Inspect, check and adjust.
• Measure the front wheel alignment.
• Inspect the brake system.
• Adjust the headlight aim.
• From the passenger compartment side, plug weld
the holed areas of the lower dashboard and front
floor with a MIG welder.
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Front Side Extension
Description
The front side extension connect the front side frames to the body and are vital to the rigidity of the entire body frame. Pay particular
attention when welding the front side extension from beneath the front floor and side sill.
Mass Production Body Welding Diagram
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