Acura RL (1996-2004 year). Instruction — page 8

Exterior Body Parts

Replacement

Mounting bolts Torque:

6X1.0 mm : 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft)

8X1.25 mm : 22 N-m (2.2 kgf-m, 16 Ibf-ft)

*8X1.25 mm: 28 N-m (2.9 kgf-m, 21 Ibf-ft)

10 X 1.25 mm: 38N-m (3.9 kgf-m, 28 Ibf-ft)

Sealing locations

NOTE: Seal the following areas to prevent

water leak and rust.

Mastic sealer: 3M #08654

Use materials above or equivalents.

NOTE: Adjust the clearance with the doors, refer

to the Service Manual for door striker adjust-

ment.

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Front Bulkhead

Description

The front bulkhead is joined to the front wheelhouse and front side frame. It forms the base for the headlights and other parts and

maintains the rigidity of the front section of the body. Pay particular attention to twists and parallelism and check mounting of

related parts when welding.

Mass Production Body Welding Diagram

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Replacement

1 . Remove the related parts.

• Front bumper

• Hood

• Right and left headlights

• Right and left front fenders

• Radiator, condenser

• Hood latch

2. Roughly pull out and straighten the damaged area.

• Check the damage to the front wheelhouse and

front side frame before removing the front bulkhead.

Use the frame straightener to roughly pull out and

repair the damaged bulkhead before removing the

bulkhead.

NOTE: Check the fit of the door, taking care not to pull

the damaged area out more than necessary.

• Use the horizontal pinch weld clamps and attach the

car to the frame straightener at the clamping points

securely.

3. Keep the body level.

Jack up the body, and place safety stands at the four

designated places of the side sills.

NOTE: Refer to the Acura 3.5RL Service Manuals for

safety stand location points.

4. Cut and pry off the front bulkhead.

• Center punch around the spot weld imprints.

• Use the special spot cutter to drill holes at the spot

weld nuggets on the front wheelhouse and front side

frame.

NOTE: When drilling holes be careful not to drill down

to the front wheelhouse or front side frame themselves.

• Cut off the bulkhead with an air chisel, leaving the

welding flanges intact.

• Level and finish the burrs from the pried off spot

welds with a disc sander.

To prevent eye injury, wear goggles

or safety glass whenever sanding, cutting or

grinding.

5. Mold the damaged related parts.

• Use a hammer and dolly to mold the damaged areas

of the front wheelhouse front and side frame.

• Even out the welding flanges with a hammer and

dolly.

• Fill all drilled holes by MIG or gas welding.

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Front Bulkhead

Replacement (cont’d)

6. Set the new front bulkhead.

• Grind both sides of the welding section of the bulk-

head with a sander to remove the undercoat and

expose the steel plate.

To prevent eye injury, wear goggles

or safety glasses whenever sanding, cutting or
grinding.

• Clamp both the right and left sides with the vise-

grips.

NOTE: Apply the spot sealer to the welding surface,

when spot welding.

• Check the front bulkhead position using the body

dimensional drawings (see

section 6

).

7. Measure the front compartment diagonally.

Measure the front compartment diagonally with a track-

ing gauge or convex tool as shown to check it for

twisting or bending.

8. Tack weld the new front bulkhead.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

Spot weld the clamped sections.

NOTE: Make sure that the right and left bulkheads are
in line with each other.

9. Temporarily assemble the hood, headlight and front

fender, then check the clearances and level differences.

10. Perform the main welding.

• Spot weld the bulkhead as shown.
• 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.

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