Acura RL (1996-2004 year). Instruction — page 12

Replacement

1. Remove the related parts.

• Front seat

• Carpet

• Refer to the front side frame (see page

4-13

).

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.

8. Apply the sealer (see

section 5

) .

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

section 7

).

• 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

section 6

).

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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