Acura RL (1996-2004 year). Instruction — page 16

4. Mold the inner panel and related parts.

• Fill and holes drilled 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, etc. with a disc sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Remove the undercoat from both sides of the weld

flange with a sander to expose the steel plate.

6. Set the repair part.

• Install the outer panel and clamp it with vise-grips.

NOTE: Apply the spot sealer to the welding surface when

spot welding.

5. Cut the replacement part.

• Cut so that the repair part overlaps the side sill by 30

mm (1.2 in).

• Apply body paint to the back of the repair part.

• 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.

• Check the body dimensions (see

section 6

).

7. Tack weld the repair part.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

Temporarily spot weld the panel at the clamped posi-

tions.

8. Remove the vise-grips and check the alignment of the

door and trunk lid.

NOTE:

• Check for flushness of the front fender, door, and

the rear fender and make sure the body lines flow

smoothly.

• Check the rear window openings.

(cont’d)

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Table of Contents

Rear Side Outer Panel

Replacement (cont’d)

9. Perform the main welding.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

• Weld the outer panel at the rear pillar and side sill with

a MIG welder.

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

holes drilled.

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

repair part, and the wheel arch extension with a MIG

welder.

10. Finish the welded areas.

• Level the MIG welded areas with a disc sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or

grinding.

• Even out high areas with a hammer. Be careful not to

deform them.

• Even out the spot welded flange areas with a ham-

mer and dolly.

• Fill in deformations and level differences of the

welded areas with solder or putty, then finish.

11. Apply the sealer (see

section 5

).

Apply sealer to the fuel fill section, trunk lid opening

joint and around the taillight area of the rear panel.

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.

Apply undercoat to the wheelhouse and apply anti-rust

agent to the inside of the outer panel (see

section 7

).

14. Install the related parts.

Install in the reverse order in which they were removed.

15. Inspect, check, and clean.

• Adjust the clearance with the door and trunk lid, then

adjust the level differences and fit. Check operation.

• Test for leaks in the trunk and passenger compart-

ments.

• Clean the trunk floor.

Main Menu

Table of Contents

Rear Panel

Description

The rear panel is joined to the rear outer panel and rear floor, and maintains the rigidity of both sides of the rear body. It must

be welded carefully.

Mass Production Body Welding Diagram

Main Menu

Table of Contents

Rear Panel

Replacement

1. Remove the related parts.

• Rear bumper

• Rear bumper upper beam
• Trunk lid lock and its attachments

• Other related parts

• Rear and side trim panels

• Taillights

2. Pull out and straighten the damaged area.

• Pull out the related rear side inner panel, rear floor,

rear frame and other damaged parts with the frame

straightener.

• Attach the car to the frame straightener by tighten-

ing the underbody clamps located at the jack-up

points on the bottom of the side sill and the side sill

side flanges.

3. Cut and pry off the rear panel.

• Cut along the bold line shown with a gas cutter or an

air chisel and remove the rear panel.

• Center punch around the spot weld imprints with the

rear side outer panel and rear floor.

• Drill holes using the spot cutter.

NOTE: Be careful not to let holes penetrate through to
the rear floor.

• Remove weld flange with a chisel.

4. Mold the related parts.

• Repair the rear floor pocket if necessary (see page

4-40

).

• Repair all cracks, holes or other defects by MIG or

gas welding.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

5. Set the new rear panel.

• Paint the inside of the panel with the body color.

• 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.

• Remove the undercoat from the welding section of

the panel and expose the steel plate using a disc
sander.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or
grinding.

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