Acura TL (1995-1998) body repair. Manual — part 13
Windshield Lower
Replacement
WINDSHIELD LOWER
CENTER DEFROSTER
DUCT
DASHBOARD
UPPER
A/C DUCT SHELTER
WINDSHIELD
LOWER
1. Remove the related parts.
Wiper arm and motor
Windshield
Right and left front fenders
Right and left front door opening trims
Front pillar trim
Hood
Dashboard, etc
Wire harnesses and electrical accessories
Steering column
2. Cut the windshield lower and separate the welded
flange.
• Center punch around the spot weld imprints.
• Drill holes with a spot cutter through the nuggets.
• Peel off the welding flange using a chisel.
• Level off and finish the burrs of the pried-off spot
welds with a sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
LOWER SUPPORT
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LOWER SUPPORT
A/C DUCT
SHELTER
DASHBOARD
UPPER SIDE
BULKHEAD
CENTER
DEFROSTER
DUCT
DASHBOARD UPPER
3. Set the new windshield lower.
• Apply an undercoat and body paint to the inside.
• 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.
• Sand off the undercoat down to the metal from both
flanges to be welded.
• Clamp the new windshield lower in place with vise-
grips and squill vises.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Install the new windshield and check for proper
installation and alignment.
4. Tack weld the new windshield lower.
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
hood. Check for differences in level and clearance.
5. Perform the main welding.
• 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.
6. Finish the welding section.
Smooth the mating surface with the windshield with a
hammer and dolly.
).
Apply sealer to the upper dashboard, pillars, etc.
8. Install the front fender and hood.
Check the front fender and hood for differences in level
and clearance.
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 anti-rust agent to the inside of the windshield
lower and dashboard upper (see
).
11. Install the related parts.
Install in the reverse order of removal.
NOTE: Take care not damage the windshield and the
paint finishes.
12. Inspect and clean.
• Check the windshield for water leaks.
• After installing the dashboard, check the lights,
gauges, etc. for proper operation.
• Clean the interior.
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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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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.
• Cut the side sill with a handsaw along the bold line
shown in the figure to the right.
NOTE: Be careful not to cut the inside sill. This could
result in extensive repair.
REPAIR
PART
REPAIR
PART
30 mm
(1.2 in)
REPAIR
PART
• 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.
• 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.
SIDE SILL
OUTER PANEL
OUTER
PANEL
CENTER PILLAR
OUTER
CENTER INNER
PILLAR
30 mm
(1.2 in)
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