Acura RL (1996-2004 year). Instruction — page 13

5. Mold the related parts.

Fill any holes by MIG or gas welding, and even out with a

hammer and dolly.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

6. Set the new front pillar lower stiffener and repair part.

• Align the repair part with the top cut section, then

cut it with a handsaw.

NOTE: Cut the side sill joint with a handsaw leaving an

overlap of 30 mm (1.2 in).

• Remove the undercoat from both sides of the areas

to be spot welded with a sander to expose the steel

plate.

NOTE: Apply the spot sealer to the welding surface

when spot welding.

• Clamp the new front pillar lower stiffener and repair

part.

• Check the body dimensions (see

section 6

).

• Temporarally install the door, and check the door

hinge mounting position.

• Remove the repair part and MIG weld the front pillar

lower stiffener.

7. Tack weld the clamped sections.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

8. Temporarily mount the door and front fender.

• Remove the vise-grips, then mount the door.

• Check the clearance and level differences of the

door and fender.

9. Perform main welding.

• Weld the front pillar and side sill outer joints with a

MIG welder.

• Make 20% to 30% more spot welds than there were

holes drilled.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Make 5 mm (0.2 in) holes in the MIG weld holes with

the repair part, and weld the lower stiffener, upper

stiffener and dashboard upper side member with a

MIG welder.

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Front Pillar (Outer Panel)

Replacement (cont’d)

• Weld the front pillar extension.

10. Finish the welding areas.

• Finish grind the finishing allowance with a disc

sander until it is smooth.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Smooth the flanged section of the door opening

with a hammer and dolly.

11. Apply the sealer (see

section 5

).

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 anti-rust agent to the inside of the front pillar, front

pillar extension and side sill (see

section 7

).

14. Install the related parts.

• Install in the reverse order of removal.

• Check the door for proper installation and level

difference from the fenders.

15. Clean and check.

• After installing the dashboard, check the lights and

gauges for proper operation.

• Clean the passenger compartment and check for

water leaks.

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Side Sill (Outer Panel)

Description

The side sill should, depending on the degree of damage, be repaired as much as possible rather than replaced. (Repair by pulling

out with slide hammer with pin and washer welded on.)

Mass Production Body Welding Diagram

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Side Sill (Outer Panel)

Replacement

1. Remove the related parts.

• Front and rear doors

(remove according to part damaged)

• Side and center pillar trim

• Door opening trim

• Carpet

• Door switch

• Seat belt

2. Pull out and straighten the damaged area.

Damage may extend to the inner pillar, the inside sill and

floor. Determine the extent of the damage first, so that

the frame can be pulled out properly.

3. Cut and pry off the side sill.

• Check the damage on the outer side sill, then cut the

repair outer side sill so it will overlap by 30 mm (1.2 in)

in the front and back.

NOTE: Be careful not to cut the inside sill. This could

result in extensive repair.

• Center punch around the spot weld imprints on the

welded flange.

• Drill holes using the spot cutter.

• Pry off the welded flange with a chisel.

NOTE: Be careful not to let the holes penetrate down to

the inner section.

NOTE: Do not cut or damage the upper stiffener and

center pillar separator.

• If the damage involves part of the center pillar and

rear wheel arch, cut them as shown with a handsaw.

• Cut the side sill with a chisel leaving the weld flanges

intact.

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