Acura RL (1996-2004 year). Instruction — page 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

1-7

).

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.

11. Apply the sealer (see

section 5

).

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

section 7

).

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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