Acura RL (1996-2004 year). Instruction — page 14

• Replace the lower stiffener if necessary.

5. Set the new lower stiffener and repair part.

• Sand off the undercoat from both sides of the welded

flange on the lower stiffener and repair part.

• Clamp the new lower stiffener and repair part.

NOTE: Apply the spot sealer to the welding surface when

spot welding.

• Check the body dimensions (see

section 6

).

• Temporarily install the door, and check the door

hinge mounting position.

• Remove the repair part and MIG weld the lower

stiffener.

4. Mold the related parts.

• Fill any holed areas by MIG or gas welding.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Level and finish burrs at welded areas with a disc

sander, then even them out with a hammer and

dolly.

• Sand off the undercoat from both sides of the flange

to be welded.

NOTE: Check the damage of the honeycomb floors and if

necessary replace it (see page

4-46

).

6. Tack weld the repair part.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Remove the vise-grips and install the fender and

doors. Check for differences in level and clearance.

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Side Sill (Outer Panel)

Replacement (cont’d)

7. Perform main welding.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Weld the side sill and rear side outer joints with a MIG

welder.

• Spot weld the side sill flanges.

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

holes drilled.

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

the repair part, and weld the center pillar stiffener and

wheel arch extension with a MIG welder.

• Level the weld beads at the front and rear with a disc

sander. Hammer down the projections, then fill with

solder or putty to finish.

8. Apply the sealer.

Apply sealer to the mating surfaces of the floor and

inside sill (see

section 5

).

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, and apply an anti-rust agent

to the inside of the side sill and center pillar (see

section

7

).

11. Install the related parts.

• Install in the reverse order of removal.

• Check the door for proper installation and level

differences from the fenders.

12. Clean and check.

Clean the passenger compartment and check for water

leaks.

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Roof Panel

Description

Deformation of the roof panel is highly noticable in terms of the vehicle’s outer appearance.

Before replacing the roof rail, make sure that the body is horizontal. Before welding the roof panel, adjust the roof rail flanges so

that they contact the roof panel.

Mass Production Body Welding Diagram

NOTE: When replacing the outer panel, drill holes at the

area joined to the roof side rail and rear inner panel as

shown.

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Roof Panel

Replacement

1. Remove the related parts.

Windshield

Rear window

Sunvisor

Ceiling lights

Headliner

Moonroof frame (For some types)

2. Pull out and straighten the damaged area to approxi-

mately the original shape.

NOTE: Check the inner front pillar and the inner center

pillar for position and damage.

Cut the roof panel and pull out the pillars if necessary.

• Pull out the damaged area with the frame straight-

ener before removing the roof panel.

• Attach the car to the frame straightener by tighten-

ing the underbody clamps located at the horizontal

pinch welds.

3. Keep the body level.

NOTE: Refer to the 96 Acura 3.5RL Service Manual for

safety stand location points.

Jack-up the body at the front and back. Place safety

stands at the four designated places of the side sills.

NOTE: Make sure that the right and left pillars are

parallel with the windshield surface. Check the door for

proper opening and closing.

4. Cut off the shaded areas of the roof panel.

• Cut the roof rail weld flange with a handsaw at the

four corners.

• Using a chisel, pry off the roof panel along the bold

lines as shown.

• Center punch around the spot weld imprints of the

roof gutter welded flange.

• Drill holes using the spot cutter.

• Using a chisel, pry off the welded flange.

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