Engine and Exhaust

ELECTRICAL AND ELECTRONIC

1. Always ensure the battery is properly connected to the vehicle prior to attempting to start engine.
2. Don't disconnect the battery when the engine is running.
3. Fully release locks prior to disconnecting connections, ensure connectors are fully seated and all insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure.
5. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create any arcing to check the continuity of a circuit.
8. When charging battery, ensure battery cables are removed.
9. When replacing electronic components, disconnect the battery ground.
NOTE: Before removing battery ground, record stored trouble codes. ECM memory will be erased when ground cable is removed.
10. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary.
11. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin.
12. Avoid getting water on any of the Fuel or Engine Control System Components.
13. Fuel and Engine Control System wiring should be at least 4 inches away from high tension cables.
14. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters.
15. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself.
16. Always use recommended power source in each testing procedure.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble the control unit.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 volts to start engine.
20. In cases of electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, ECU and radio.
21. In case of temperature above 176°F (80°C), (example: infra-red spray booth), remove all ECMs.
22. The battery produces a hazardous gas (hydrogen), avoid creating sparks near battery.


FUEL SYSTEMS

1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be damaged.
4. Always use new gaskets or O-rings when installing fuel lines or injectors.
5. Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid.
6. After servicing fuel system, check for leaks and correct as needed.

ENGINE AND EXHAUST

1. On vehicles equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL".
b. Avoid running out of fuel.
c. In case of poor engine operation (misfiring), avoid driving the vehicle and repair as soon as possible.
d. Do not disconnect a spark plug wire with the engine running.
e. Avoid push starting the vehicle.
f. If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor.
3. When performing a compression test, remove the fuel pump relay. (This will prevent fuel from being fed to the injectors).