Acura TL 1995 1998 User Manual

1995-1998 2.5TL/3.2TL Body Repair Manual

INTRODUCTION

How to Use This Manual

Body Repair

Preparation of Work

This manual covers the repairs of 1995-1998 Acura 2.5TL/3.2TL automobiles which have been involved in accidents, and it describes the work related to the replacement of damaged body parts.

Please read through these instructions and familiarize yourself with them before actually using this manual. NOTE: Refer to the 1995-1998 Acura 2.5TL Service Manual (P/N 61SW504) and 1996-1998 Acura

3.2TL Service Manual Supplement (P/N 61SW505) for specifications, wire harness locations, safety stand support points, etc.

Special Information

WARNING

Indicates a strong possibility of severe personal injury or death if instructions are not followed.

CAUTION

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

NOTE: Gives helpful information.

CAUTION

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause PERSONAL INJURY, damage a vehicle, or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized.

Welding Methods/ Repair Tools

General Information

Replacement

Cross Section of Body and

Sealants

Body Dimensional

Drawings

Rust-preventive Treatments

All information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables.

HONDA MOTOR CO., LTD.

Service Publication Office

Paint Repair

Body Paint Repair

Resin Parts Paint Repair

(Exterior)

Service Precautions

General Safety Precautions

Preparation of Work

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Description

• Most monocoque bodies are composed as a single unit by welding together pressed parts made of steel plates which come in a variety of different shapes and sizes. Each part is responsible for displaying a certain strength and durability in order that it may play its role in meeting the functions of the body as a whole.

Damage to the exterior of the body can be inspected visually, but where there has been an external impact, it is necessary to inspect the extent of the damage. In some cases, the deformation has spread beyond the actual areas which were in the collision and so this has to be inspected closely.

Checkpoints

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• Accurate Inspection of Damaged Parts (Visual)

Seat Belts Replace the seat belts if:

1. The belt material is cut, punctured, burned or in any way damaged.

2. The buckle or retractor does not work properly.

3. They were being worn at the time of a collision (check for damage at the seat belt anchor points).

4. Their condition is questionable.

Front Section:

1. Is there any bending, splitting, denting or other damage to the suspension and its related parts?

2. Is there any deformation of the front bulkhead or radiator core? Have any of the connected sections come apart?

3. Are there any creases or distortion in the front wheelhouse or side frame? Have any of the connected sections come apart?

4. Is there any bending or twisting of the whole front area?

5. Is there any deformation like creases, bulges, or dents in the front pillar, dashboard, floor, etc.?

6. Is there any vertical twisting or misaligned clearance in the door?

7. Is the windshield seal broken?

8. Is there any deformation in the vicinity of the top part of the roof panel's center pillar?

9. Is there any damage inside the automobile (is there any twisting of the dashboard, or anything irregular with the clearances or sheet-mounting parts)?

10. Is there any damage to the steering wheel? Is there any deformation in the column and the column-mounted parts?

11. Is there any oil or water leakage and damage to the engine, transmission or brakes?

12. Is there any irregular noise in the gear changing operation, engine and transmission rotation?

13. Are there any traces of contact between the engine block and the dashboard lower panel?

14. Is there any damage to brake or fuel lines, or wire harnesses?

Rear Section:

1. Is there any twisting, bulging or denting of the rear floor and rear bolsters? Have any of the connected sections come apart?

2. Is there any irregular bulging or denting in the rear fender?

3. Is there any distortion in the rear inner panel? Is there any bending and denting in the vicinity of the rear pillar?

4. Is there any distortion or creasing is the rear wheelhouse and arch sections? Have any of the connected sections come apart?

5. Is there anything irregular in the rear glass and quarter glass seal clearance?

6. Is there any twisting or misalignment of the clearance of the trunk lid or tailgate opening section?

7. Is there any bending, splitting, denting or other damage to the suspension and its related parts?

8. Is there any deformation of the rear floor, rear floor cross member and damper base? Have any of the connected sections

come apart?

Preparation of Work

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Correction of the Damaged Area

Set the frame corrector on the car body. The side sill is flangeless to allow reshaping by pulling it out. Use the horizontal pinch welds for anchoring the car.

Underbody Clamp Specifications:

UNDERBODY CLAMPS

1. Apply load to the damaged section and pull it out until

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the section is almost restored to the original shape.

8. Weld the replacement parts. Welding methods (see section 2).

2. Check that the parts of the body they cover have been more or less restored to their original shapes.

NOTE: Check the original position using the body dimensional drawings (see section 6) and the positioning jigs (see page 1-7).

3. Remove the parts that require replacement.

4. Decide whether to replace all the affected parts or

whether to cut the weld joint parts and replace them.

5. Cut off and separate the damaged parts.

NOTE: When cutting the parts off, take special care that you do not damage adjacent parts on the automo-

bile.

Setting Condition of Replacement Parts Joint Sections:

• Make sure that you can perform straightening work after welding.

• Make sure that the locations are not susceptible to distortion caused by other parts.

• Make sure that there are few removable parts and that the location allows safe welding.

• Make sure that the joints are short, and that paint repair can be performed easily.

• Make sure the locations are such that the joints can be finished in a way that does not affect the outward appearance.

• Make sure that the locations do not hinder the removing and attaching of parts. NOTE: Bear in mind all of these conditions, and after determining the joint locations, cut the joints for an overlap of 20~30 mm (0.8~1.2 in).

NOTE: Use of the positioning jig is recommended.

CAUTION: Protect body parts with the heat-resistant protective cover to prevent damage, when welding.

The paint film, which is designed to prevent corrosion

caused by moisture, is destroyed around the edges of the locations which have been repaired by welding.

Therefore, in such places and especially in those areas

which are not visible, apply another coat of the paint, referring to the anti-corrosion painting manual. This operation is designed to maintain durability and quality (see section 7).

6. Mold the related parts.

7. Set and tack weld the replacement parts.

NOTE: Temporarily mount the related parts and check

the clearance and level differences.

Preparation of Work

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Measurement (Excluding small damage)

Whenever possible, make judgements and conclusions based on measurement. Measure the wheel alignment (see page 1-2) so as to prevent any future trouble like unsymmetrical wear of the tires or catching of the steering wheel.

If there are any deviations, use a tram tracking gauge and measure parts of the body.

POINTER A

If there is any twisting to the body, measure using a frame centering gauge.

When measuring body dimensions, use a universal tram gauge.

Positioning Jigs

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4-12,

4-18, 4-50, 4-55

4-12,

4-18

4-50, 4-55

Welding Methods/Repair Tools

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Spot Welding

Spot welding is also known as resistance spot welding, and it is the most suitable method of welding for automobiles. It has three

main features: the welding can be performed instantaneously, it exercises very little effect on the mother material, and it reduces the generation of distortion to the absolute minimum. However, please remember to remove all paint and other impurities from the surface of the material you intend to weld for reliable results.

Welders:

Spot welder

Welding Conditions:

When performing spot welding, make absolutely sure that you conform to the conditions governed by the current, conductivity

time, welding pressure, holding time, and shutdown time recommended for the spot welder.

Please bear in mind the following points when welding:

• Plate thickness and minimum welding pitch

NOTE: When the welding intervals are too

small, this leads to branching, making it im-

possible to maintain the desired soldering

state.

• Plate thickness and tip diameter

Timer

• Welding Strength Test

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Even if you perform the welding in accordance with the conditions, the strength of the welded sections may fluctuate widely with

drops in the voltage and other factors. The quality of the welding cannot be evaluated unless the welded sections are destroyed.

Provide yourself with a steel plate of the same thickness and conduct a destruction test.

• If holes appear in the steel plates, this means that the welding is standard strength.

• Drive a wedge between two panels near the nugget. If the welded parts do not come apart and the diameter of the nugget is more than 3mm (0.1 in), the welding

should be satisfactory.

WEDGE

30 mm

(1.2in)

Stop inserting the wedge when the full size of the nugget appears.

NOTE:

It is difficult to perform spot welding in the following circumstances:

• When it is not possible to remove any rust or paint attached to the welding surfaces.

• When the tip of the spot welder cannot be inserted into the welding section.

• When the welding surfaces can be seen from the outside and welding will impair the exterior appearance.

In all these cases, the gas welding method should be employed. Moreover, if it is not possible to perform spot welding because of

space restrictions, plug welding using on the arc welding method may be performed instead. For plug welding, the sections to be

welded must be close together.

Welding Methods/Repair Tools

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Gas Welding

Gas welding is indispensable for body repair because of the broad range of its applications for joining the body panels, cutting the

materials that construct the body, and applying heat to reform panels, and also because it is easy to get hold of the tools.

However, this method requires experience.

Welders:

Gas regulator

Welding Methods:

Gas regulator

Welder

Cutter

Oxygen/Acetylene tanks

Butt welding

Fillet welding or soldering

Carbon Dioxide Arc Welder (MIG Arc Weld)

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This welding process uses inexpensive carbon dioxide instead of expensive inert gases as a shielding means. Consumable metal electrodes are employed. It has a wide range of applications, including butt welding of thin plate, fillet welding, plug welding, and

MIG spot welding. In terms of the weld strength, it is also highly stable.

Welders:

CAUTION: Disconnect the negative battery cable before arc welding.

Welding Methods:

Butt Welding

Fillet welding

Spot welding Plug welding

Welding Methods/Repair Tools

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Examples of Repair Tools

Item

Protective tools

Operator

Work

Tools, equipment used

1. Protective goggles

2. Cap

3. Ear plug

4. Shield for eyes

5. Overalls with long sleeves

6. Dust-proof mask

7. Protective apron

8. Welding gloves

9. Foot protectors

10. Safety shoes

11. Work gloves

12. Spattering guard

Processing tools

Vehicle body

Plug hole drilling

Heat-resistant protective cover.

DRILLING BLADE, DRILL, SPOT CUTTER

PUNCH

PRESSURE DRILL

Flange tools

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Item

Work

Edge preparation

Tools, equipment used

Cutting tools

Cutting

AIRSAW

AIR IMPACT CUTTER

AIR JIGSAW

HANDSAW

HAND NIBBLER

CHISEL

Sanding tools

Cleaning

PLASMA CUTTER

DISC SANDER

Air type: Electric type:

BELT SANDER

Welding Methods/Repair Tools

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Examples of Repair Tools (cont'd)

Fixing tools

Shaping tools

Item

Work

Base metal fixing

Skin panel shaping

VISE-GRIPS

HAMMERS

Tools, equipment used

SCREW CLAMP

SQUILL VISES

DOLLIES CHISEL

SNIPS/ SHEARS

Body, frame shaping

SPOONS

WELDER

BODY JACK

SLIDE HAMMER

General Information

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Zinc-plated Steel Plate Repair

The zinc-plated steel plate used in some panels of the Acura 2.5TL/3.2TL requires different repair techniques than ordinary steel plate. Refer to "Body Construction" (see page 4-2) for the location of the zinc-plated panels.

ZINC PLATING (5~6 microns)

Steel plate

1. Before spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. Apply sealer to the flange after welding.

To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

NOTE: Seal the sanded surfaces thoroughly to prevent rust.

2. The electric continuity properties of zinc-plated steel plate is different from ordinary steel plate. When spot welding, increase the current by 10-20%, or increase the resistance welding time.

Increase the number of weld spots by 10-20% also.

NOTE: The MIG welding procedures for zinc-plated steel plate are the same as for ordinary steel plate.

To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety

shoes.

3. Before applying putty or body filler to the zinc-plated steel plate, sand the zinc plating thoroughly to promote adhesion and prevent blistering.

NOTE:

• Use only epoxy-based putties and fillers on zinc-plated steel plate.

• Follow the manufacturer's specification.

4. When performing paint work, apply caulking to the ground wire mounting position to mask the body.

SPECIAL BOLT

CAULKING

GROUND WIRE

MOUNTING HOLE

Avoid puttying as much as possible when repairing a new car. Use alternative methods as much as possible.

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• Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container. Spray paint only in a well ventilated area.

• Cover spilled paint with

sand,

or wipe it up at once.

• Wear an approved respirator, gloves, eye protection and appropriate clothing when painting. Avoid contact with skin.

• If paint gets in your mouth or on your skin, rinse or wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention.

• Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.

General Information

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Door and Bumper Reinforcement Beams

Door and bumper reinforcement beams used on Honda automobiles are made from a metal equivalent to High Strength Steel (except

2.5TLfront

Should High Strength Steel be heated, the strength of the steel will be reduced. If High Strength Steel is damaged, as in a automobile accident where the door reinforcement beams are bent, the beams may crack should any attempt be made to straighten them.

2.5TL

For this reason, Door and Bumper Reinforcement Beams should never be repaired, they should be replaced if they become damaged.

NOTE: If a door beam is damaged, the whole door panel assembly should be replaced.

bumper reinforcement beam).

front bumper reinforcement beam is made of aluminum alloy (#6000).

FRONT DOOR REINFORCEMENT

BEAM

REAR DOOR REINFORCEMENT

BEAM

2.5TL:

3.2TL:

FRONT BUMPER REINFORCEMENT BEAM

(Aluminum alloy)

FRONT BUMPER REINFORCEMENT BEAM

(High Strength Steel)

REAR BUMPER REINFORCEMENT BEAM

(High Strength Steel)

vffMr/////////////////////^

Wmmm/mmm//////^/),

Construction

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NOTE: Be sure to use epoxy-based putty and primer

surfacer

to make any repairs on paint coats or zinc-plated sheet metal (see page 3-3).

Front Fender

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Replacement

NOTE: Check clearance and level differences of the hood, door panels and front bumper.

Remove the related parts.

• Front bumper

• Headlight

• Mud guard

• Side sill panel

• Inner fender

2. Mask parts with tape. Stick masking tape on the neighboring lower windshield and the door to protect painted surfaces from damage.

3. Remove the front fender mounting bolts.

FRONT FENDER

5. Set the front fender. Fasten to the front wheelhouse at two spots with bolts. Close the hood and check the front and rear clearances, door clearance and level differences.

MOUNTING BOLT

NOTE: Apply the mastic sealer to the mounting positions of the front fender.

MASTIC SEALER

4. Apply paint on the back of the new fender. 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 paint container.

• Avoid contact with skin. Wear an approved

respirator, clothing when painting.

• Paint is flammable. Store it in a safe place, and keep it away from sparks, flames or cigarettes.

NOTE: Apply paint to lower section of front pillar also.

gloves,

eye protection and appropriate

6. After checking the mounting position, tighten all bolts fully.

7. Apply the undercoat (see section 7 Apply an undercoat to the inside of the front fender and upper face of the front wheelhouse.

8. 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.

9. Install the related parts. Install in the reverse order in which they were

10. Check and adjust.

• Check wiring connections.

• Adjust the headlight aim.

removed.

Front Bulkhead

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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

Mass Production Body Welding Diagram

welding.

2.5TL:

3.2TL:

Replacement

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Remove the related parts.

• Front bumper

• Hood

• Right and left headlights

• Right and left front fenders

• Radiator, condenser

• Hood latch

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.

-1

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 staightener 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.

Keep the body level.

Jack up the body, and place safety stands at the four designated places of the side sills.

To prevent eye or safety glass whenever sanding, cutting or grinding.

2.5TL:

FRONT SIDE FRAME

FRONT LOWER

CROSS MEMBER

3.2TL:

injury,

wear goggles

BULKHEAD UPPER FRAME

FRONT SIDE BULKHEAD

NOTE: Refer to the Acura

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.

2.5TL/Acura

3.2TL

Service

Front Bulkhead

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Replacement

(cont'd)

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.

2.5TL:

FRONT SIDE FRAME

3.2TL:

FRONT WHEELHOUSE

7. 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.

8. Measure the front compartment diagonally. Measure the front compartment diagonally with a tracking gauge or convex tool as shown to check it for twisting or bending.

FRONT SIDE FRAME

6. Set the new front bulkhead.

• Grind both sides of the welding section of the bulkhead with a sander to remove the undercoat and expose the steel plate.

U^^JQQ

or safety glasses whenever sanding, cutting or grinding.

• Clamp both the right and left sides with the visegrips as shown.

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).

prevent

eye

injury,

wear

goggles

9. Temporarily assemble the hood, headlight and front fender, then check the clearances and level differences.

10. Perform the main welding.

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• 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.

2.5TL:

3.2TL

3.2TL:

12.

Apply the undercoat (see section

13.

Attach the front fender.

14.

Lower the body.

7).

NOTE: Tighten the wheel nuts to the specified torque. Torque: 108

N-m

(11.0

kgf-m,

79.6

Ibf-ft)

11.

Finish the welds.

Use a hammer and dolly to even out the front wheelhouse and front side frame flanges for a close fit with the surface of the front

bulkhead.

2.5TL:

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 electical components light up and operate properly.

• Replenish radiator coolant and inspect for leaks.

Front Wheelhouse/Damper Housing

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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.

Front Wheelhouse/Damper Housing

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Mass Production Body Welding Diagram

2.5TL:

3.2TL:

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Front Wheelhouse/Damper Housing

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Replacement

Remove the related parts.

• Parts to be removed when removing the front bulkhead

• Parts on passenger side of lower dashboard which are especially flammable

• Electrical accessories in engine compartment and wire harnesses.

2.5TL

NOTE: See the 95-96 Acura Service Manuals, for removal and installation of the engine, front suspension and brakes.

2. Pull out and straighten the damaged area to approximately the original shape.

• Attach the car to the frame straightener by tightening the underbody clamps at the horizontal pinch

weld points.

NOTE: Refer to the 95-96 Acura 2.5TL & 96 Acura 3.2TL Service Manuals 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).

& 96 Acura

3.2TL

4. Cut and pry off the front wheelhouse and damper housing.

-1.

When replacing the front wheelhouse only.

• 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.

2.5TL: FRONT WHEELHOUSE

NOTE: Check the condition of the door and hinges.

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.

3.2TL:

FRONT WHEELHOUSE

-2.

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Replace the damper housing with the front

wheelhouse.

• Remove the wheelhouse upper rear member.

• Remove the MIG weld flange with a disc sander.

To prevent eye injury, wear goggles or

safety glasses whenever sanding, cutting or grinding.

2.5TL:

DASHBOARD UPPER SIDE MEMBER

• Using a chisel,

front pillar and damper housing.

NOTE: Remove the wheelhouse upper rear member

carefully so they can be reused.

2.5TL:

pry

off the welded flange form the

WHEELHOUSE UPPER REAR MEMBER

3.2TL:

DAMPER HOUSING

FRONT SIDE FRAME

DASHBOARD UPPER SIDE MEMBER

FRONT PILLAR INNER LOWER

3.2TL: WHEELHOUSE UPPER REAR MEMBER

Front wheelhouse/Damper housing

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Replacement

5. Mold the related parts.

• Level and finish the burrs left on the welding surfaces with a sander.

• Fill all drilled holes by MIG or gas welding.

Use a hammer and dolly to even out the welded areas of the lower dashboard, front side frame and dashboard upper side member.

2.5TL:

DAMPER HOUSING

FRONT SIDE FRAME

(cont'd)

3.2TL:

WHEELHOUSE UPPER MEMBER DIAGONAL

WHEELHOUSE UPPER EXTENSION

• 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 respirator, gloves, eye protection and appropriate clothing when painting.

• Paint is

• Remove the undercoat from both sides of the weld-

or safety glasses whenever sanding, cutting or grinding.

• Clamp to the front side frame with vise-grips and

NOTE: Apply the spot sealer to the welding surface

when spot welding.

• Clamp the front bulkhead with vise-grips.

• Measure the front compartment diagonally.

NOTE: Use of a positioning jig is recommended (see page 1-7).

flammble.

keep it away from sparks, flames or

ing section and expose the steel plate using a disc sander.

squill vises.

skin.

Wear an approved

Store it in a safe place, and

To prevent eye

injury,

wear goggles

cigarettes.

DASHBOARD UPPER SIDE MEMBER

DASHBOARD LOWER

DAMPER STIFFENER

FRONT SIDE FRAME

6. Set the new front wheelhouse and damper housing.

• Apply body paint to both sides of the new front wheelhouse and damper housing.

• See Paint Repair section.

POSITIONING JIG

• Spot weld several points in the clamped sections, and temporarily attach the front wheelhouse and damper

housing.

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

7. Check the dimensions, temporarily install the hood, front fender and headlight, and check for differences in level

and clearance.

8. Perform the main welding.

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• Weld as much as possible with the jig still

To prevent eye injury and burns

when welding, wear an approved welding helmet,

gloves and safety shoes.

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

2.5TL:

mounted.

9. Weld the wheelhouse upper rear member. When the upper rear member is to be reused, make MIG welds at the drilled holes.

2.5TL:

10. Finish the welded area. Use a hammer and dolly to even out the side bulkhead

and front side frame flanges for close fit with the surface

of the front wheelhouse and damper housing.

11. Apply the sealer (see section 5).

Apply sealer to the mating surfaces of the lower

dashboard and front side frame, etc.

3.2TL:

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. Undercoat the front floor, etc, and apply anti-rust agent

to the inside of the welding section of the front side frame, lower dashboard, and upper member, etc (see

section 7).

14. Install the related parts. Install in the reverse order in which they were

15. Inspect, check and make adjustment.

• Measure the front wheel alignment.

• Inspect the brake

• Adjust the headlight aim.

system.

removed.

+ 122 hidden pages