Acura RL (1996-2004 year). Instruction — page 15

• Weld the holed areas with a MIG or gas welder.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Level and finish burrs on the welded flanges with a

disc sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Even out the roof side rail welded flange with a

hammer and dolly for a close fit with the roof panel

welded flange.

• Check the width of the groove for the roof moldings

on both sides.

• Apply the spot sealer to the welding surface when

spot welding.

5. Apply paint to the underside of the new roof panel.

• 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.

6. Set the new roof panel.

• Sand off the undercoat from both sides of the flange

sections to be spot welded to expose the steel plate.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Clamp the roof panel with vise-grips.

NOTE:

• Check that the flange surfaces fit closely. Be careful

not to twist or deform the roof panel.

• Check the body dimension (see

section 6

).

7. Tack weld the new roof panel.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Spot weld the clamped sections to temporarily install

the roof panel.

• Set the windshield and rear window, and check the

roof panel for proper installation.

• Install the roof molding and check the width of the

groove.

8. Perform the main welding.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Spot weld the roof rails at the front and rear.

• Spot weld the roof arch.
• Make 20% to 30% more spot welds than there were

holes drilled.

(cont’d)

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Roof Panel

Replacement (cont’d)

• Smooth the spot weld areas under the windshield and

rear window with a hammer and dolly.

NOTE: After welding the pillars, grind and finish the

welded areas flat and blend them into the roof panel.

9. Apply and level the sealer to the welded areas.

10. 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.

11. Apply an anti-rust agent to the inside of the roof side rail.

12. Install the related parts.

Install in the reverse order of removal.

13. Check and clean.

• Check the windshield and rear window for water

leaks.

• Make sure the moonroof operates smoothly.

• Clean the passenger compartment thoroughly.

• Weld the roof rail from the inside by MIG welding as

shown.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

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Rear Side Outer Panel

Description

The rear side outer panel is a conspicuous part of the vehicle. It is especially important for body line continuing from the door.

Therefore, pay particular attention to it when conducting work. This part also is next to the trunk lid, door and rear window and other

parts and must be aligned with them.

Mass Production Body Welding Diagram

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Rear Side Outer Panel

Replacement

1. Remove the related parts.

• Rear bumper
• Rear window

• Taillight
• Rear pillar trim panel
• Trunk side panel
• Rear seat

• Rear seat belt

• Fuel fill pipe (left side only)

Do not smoke while working near

the fuel system. Keep open flame away from the fuel

system. If necessary, remove the fuel tank and/or

lines before welding nearby. Drain fuel into an

approved container.

2. Pull out and straighten the damaged area.

NOTE: Carefully check the inner pillar and trunk gutter

for position and damage. Pull out the inner panel by

cutting the outer if necessary.

• Jack-up the body and place safety stands at the four

designated support points.

• Pull out the damaged rear side outer panel with the

frame straightener, then pull out and straighten the

center pillar inner panel and rear wheelhouse.

NOTE: Be careful not to pull out more than necessary.

• After pulling, check the inner pillar and trunk gutter

position using the body dimensional drawings (see

section 6

).

3. Cut and pry off the rear side outer panel.

• Cut at the rear pillar and side sill with a handsaw.

• Cut the panel from the body with a chisel leaving the

weld flange at the inner panel intact.

NOTE: Do not cut or damage the inner panel and rear

damper stiffener.

• Cut at the side sill or wheel arch according to the

extent of the damage.

• Center punch around the spot weld imprints on the

remaining flange.

• Drill out the spot welds with the spot cutter.

• Pry off the welded flange sections using a chisel.

Do not smoke while working near

the fuel system. Keep open flame away from the fuel

system. If necessary, remove the fuel tank and/or

lines before welding nearby. Drain fuel into an

approved container.

NOTE: Do not cut or damage the rear damper stiffener

and rear pillar separator.

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