Acura RL (1996-2004 year). Manual — part 12
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 extension 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 extension 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 extension.
• Center punch around the spot weld imprints on the
front side extension from inside the passenger com-
partment.
• Drill holes is the spot welded areas with a 5 mm (0.2
in) drill.
NOTE: Drill holes through the parts completely since the
replacement front side extension will be welded by MIG
welding.
• 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.
• 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 Extension
Replacement (cont'd)
6. Set the new front side extension.
• 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 extension 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 extension 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 extension
using MIG welds.
) .
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 extension and side sill (see
).
• Make 5 mm (0.2 in) holes in the MIG weld holes with
the front side extension, and weld the front side
frame, floor frame, side sill extension and inside sill
with a MIG welder.
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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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Front Pillar (Outer Panel)
Replacement
1. Remove the related parts:
• Hood
• Front fender
• Front door
• Windshield
• Front side trim
• Door opening trim
• Side cowl lining
• Dashboard
• Front pillar trim
• Wire harness, etc.
• Steering column
• Steering hanger pipe
NOTE: Make sure that the right and left pillars are
parallel with the windshield surface. Check the door for
proper opening and closing.
2. Pull out and straighten the damaged area.
• Pull out the damaged area with the frame straight-
ener before cutting off the front pillar extension and
front pillar.
NOTE: Pull out until the pillar is lined up with the
surface of the windshield.
• With the pillar pulled out, pull out and straighten the
related lower dashboard and floor section.
• After pulling, check the inner pillar position using the
body dimensional drawings (see
).
3. Remove the front pillar extension.
• Repair the front pillar lower stiffener if necessary.
4. Cut off the front pillar.
• Use a handsaw to cut the windshield and side sill
areas.
NOTE: Be careful not to cut the inner section.
• Center punch around the spot weld imprints.
• Drill holes using a spot cutter.
• Chisel off the weld flanges.
• Finish the burrs at the drilled areas with a disc
sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
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