Acura RL (1996-2004 year). Manual — part 9

11. Finish the welds.

Use a hammer and dolly to even out the front wheel-

house and front side frame flanges for a close fit with

the surface of the front bulkhead.

12. Apply the undercoat (see

section 7

).

13. Attach the front fender.

14. Lower the body.

NOTE: Tighten the wheel nuts to the specified torque.

Torque: 108 N-m (11.0 kgf-m, 79.6 Ibf-ft)

15. 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.

16. Install the related parts.

17. Inspect, check, and make adjustments.

• Adjust the headlight aim.

• Check that the electrical components light up and

operate properly.

• Replenish radiator coolant and inspect for leaks.

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Front Wheelhouse/Damper Housing

Description

The front wheelhouse component is constructed as a unit with the front damper housing. Therefore, replacement of the

component affects the front wheel alignment. When assembling it, either use a positioning jig or follow dimensions on the
frame repair chart for positioning. Weld carefully.

Mass Production Body Welding Diagram

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Replacement

1. Remove the related parts.

• Parts to be removed when removing the front bulk-

head

• Parts on passenger side of lower dashboard which

are especially flammable

• Electrical accessories in engine compartment and

wire harnesses.

NOTE: See the 96 Acura 3.5RL Service Manual, for

removal and installation of the engine, front suspension

and brakes.

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

mately the original shape.

• Attach the car to the frame straightener by tighten-

ing the underbody clamps at the horizontal pinch

weld points.

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

safety stand location points.

• Before cutting off the damaged sections, pull them

out so that they are restored to the original shape.

• Do not pull out more than necessary.

• Pull out and straighten the damaged area of the

lower dashboard, front pillar, and other parts.

• After pulling, check the damper housing position

using the body dimensional drawings (see

section 6

)

and positioning jig (see page

1-7

).

NOTE: Check the condition of the door and hinges.

• Center punch around the spot weld imprints on the

front side frame and damper housing.

• Drill holes in the center punched areas using a spot

cutter.

• Using a chisel, pry off the welded flange.

3. Peel off the undercoat.

Heat the undercoat at the weld areas of the wheelhouse

and front side frame with a gas torch, and peel off the

undercoat with a metal spatula.

4. Cut and pry off the front wheelhouse and damper

housing.

-1 When replacing the front wheelhouse only.

• Remove the wheelhouse upper panel.

• Remove the MIG weld flange with a disc sander.

To prevent eye injury, wear goggles or

safety glasses whenever sanding, cutting or grinding.

NOTE: Remove the wheelhouse upper panel carefully so

they can be reused.

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Front Wheelhouse/Damper Housing

Replacement (cont'd)

- 2 Replace the damper housing with the front

wheelhouse.

• Remove the front pillar extension.

• Remove the MIG weld flange with a disc sander.

To prevent eye injury, wear goggles or

safety glasses whenever sanding, cutting or grinding.

• Using a chisel, pry off the welded flange form the

front pillar and damper housing.

NOTE: Remove the front pillar extension carefully so they

can be reused.

• From the passenger compartment side, drill holes in

the spot welded area with a 5 mm (0.2 in).

NOTE: Drill holes completely through the parts since the

replacement damper housing will be welded by MIG

welding.

• Using a spot cutter, drill holes in the spot welded area

on the front side frame and dashboard upper side

member.

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