Acura RL (1996-2004 year). Manual — part 10
5. Mold the related parts.
• Level and finish the burrs left on the welding
surfaces with a sander.
• Fill all drilled holes by MIG or gas welding.
• Use a hammer and dolly to even out the welded areas
of the lower dashboard, front side frame and
dashboard upper side member.
• 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.
• Remove the undercoat from both sides of the weld-
ing section and expose the steel plate using a disc
sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
• Clamp to the front side frame with vise-grips and
squill vises.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Clamp the front bulkhead with vise-grips.
• Measure the front compartment diagonally.
NOTE: Use of a positioning jig is recommended (see
page
).
6. Set the new front wheelhouse and damper housing.
• Apply body paint to both sides of the new front
wheelhouse and damper housing.
• See Paint Repair section.
• Spot weld several points in the clamped sections, and
temporarily attach the front wheelhouse and damper
housing.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
7. Check the dimensions, temporarily install the hood, front
fender and headlight, and check for differences in level
and clearance.
(cont'd)
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Front wheelhouse/Damper housing
Replacement (cont'd)
8. Perform the main welding.
• 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.
• Make 20% to 30% more spot welds than there were
holes drilled.
9. Weld the wheelhouse upper panel and front pillar
extension.
• Plug weld the holes areas of the dashboard lower and
Damper housing with a MIG welder.
10. Finish the welded area.
Use a hammer and dolly to even out the side bulkhead
and front side frame flanges for close fit with the surface
of the front wheelhouse and damper housing.
).
Apply sealer to the mating surfaces of the lower
dashboard and front side frame, etc.
12. 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.
13. Apply the undercoat.
Undercoat the front floor, etc, and apply anti-rust agent
to the inside of the welding section of the front side
frame, lower dashboard, and upper member, etc (see
).
14. Install the related parts.
Install in the reverse order in which they were removed.
15. Inspect, check and make adjustment.
• Measure the front wheel alignment.
• Inspect the brake system.
• Adjust the headlight aim.
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Front Side Frame
Description
The front side frame acts as a base for the front suspension and is highly important in maintaining the rigidity of the front section.
Pay careful attention to the position and dimensions of the weld joints and weld carefully.
Mass Production Body Welding Diagram
NOTE: Replace the front side frame and front side extension as an assembly.
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Front Side Frame
Replacement
1. Remove the related parts.
• Front suspension related parts
• Brake hoses and pipes
• Engine compartment electrical components
• Fittings in passenger compartment, etc.
• Steering gearbox.
2. Remove the sub-frame.
NOTE: With the front bulkhead removed.
3. Roughly pull out and straighten the damaged area.
• Attach the car to the frame straightener by tighten-
ing the underbody clamps located at the horizontal
pinch welds.
NOTE: Refer to the 96 Acura 3.5RL Service Manual for
safety stand location points.
• Before cutting off the damaged sections, pull them
out so that they are restored to the original shape.
• Cutting off the front side frame before roughly
pulling out the damage makes repair of the related
front floor, lower dashboard, and other related parts
difficult.
4. Peel off the undercoat.
Heat the undercoat at the weld areas of the lower
dashboard, front floor and side sill 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.
5. Remove the front side frame.
NOTE: It's not necessary to separate the front wheel-
house from the front side frame if the wheelhouse/
damper housing is to be replaced also.
• Center punch around the spot weld imprints on the
wheelhouse, damper housing, lower dashboard, front
floor and floor frame.
• Using a spot cutter, drill holes in the spot welded
areas.
• Peel off the welding flange using the chisel.
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