Repair and Diagnosis: Service Precautions

Safety Warnings

Review carefully the General Service Health and Safety Precautions below before beginning any repair. Following these general service warnings are specific system warnings that must be carefully reviewed before beginning work on any listed system.

General Service Health and Safety Precautions

WARNING:
- Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
- Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury.
- Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate during operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and replace with a new fan as necessary. Failure to follow this instruction may result in serious personal injury.
- Vehicles with engine auto start-stop technology may start automatically with the ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating engine parts. Failure to follow this instruction may result in serious personal injury.
- Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the vehicle weight, including any vehicle cargo or modifications. Always position the hoist lift arms as shown in the illustration. Do not use the engine to power the drive wheels unless all drive wheels are elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with the ground can cause unintended vehicle movement. Failure to follow these instructions may result in serious personal injury or death.
- Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the vehicle weight, including any vehicle cargo or modifications. Identify the correct jacking points as shown in the illustration. Position the vehicle on a hard, level surface. After jacking, always support vehicle with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake and block all wheels remaining on the ground. Failure to follow these instructions may result in unintended vehicle movement and serious personal injury or death.
- Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury.
- Never support an engine by the intake or exhaust manifolds. The engine may drop suddenly. Failure to follow this instruction may result in serious personal injury.
- Disconnect the window regulator motor connector before working inside the vehicle doors. Service actions inside the door (such as door latch, handle or lock cylinder service) or operating the remote keyless entry (RKE) fob may activate the windows on vehicles equipped with global open/close. Serious injury to hands or arms may occur if a window motor is activated during service. Failure to follow these instructions may result in serious personal injury.
- Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury.
- Keep solvents away from ignition sources. Solvents may be flammable and can ignite or explode if not handled correctly. Failure to follow this instruction may result in serious personal injury.
- Use only a type-D fire extinguisher to extinguish magnesium fires. Never attempt to use a type-A, -B, -C extinguisher, or water, as these items are ineffective and may accelerate a magnesium fire. Failure to follow these instructions may result in serious personal injury.
- Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.
- Always verify that the lockpin on a bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.
- Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.
- Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when removing fasteners. Failure to follow this instruction may result in injured fingers.

Carefully review the following system safety warnings before beginning any service or repair work.

High Voltage System Health and Safety Precautions

WARNING:
- To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death.
- Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death.
- Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death.

Climate Control System Health and Safety Precautions

WARNING:
- Air conditioning R-134a liquid refrigerant is capable of harming eyes or freezing skin. Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these instructions may result in serious personal injury.
- Air conditioning R-134a refrigerant gas is capable of displacing the air necessary for breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not release a large quantity of R-134a gas within a confined space or allow it to be exposed to a high temperature flame (such as a torch). Consult the Material Safety Data Sheet for further information. Failure to follow these instructions may result in serious personal injury or death.
- Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury.
- Before disconnecting any heater water hoses, shut OFF the engine and wait until engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot liquid escaping from the engine cooling system.
- The electric booster heater may become hot during use and can burn unprotected skin. Allow enough time for the heater to cool before servicing. Failure to follow this instruction may result in serious personal injury.

Battery and Battery Charging System Health and Safety Precautions

WARNING:
- Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in serious personal injury.
- Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery.
- Battery posts, terminals and related accessories contain lead and lead components. Wash hands after handling. Failure to follow these instructions may result in serious personal injury.

Brake System Health and Safety Precautions

WARNING:
- Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.
- Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

Body Repair Health and Safety and General Precautions

WARNING:
- Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury.
- Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury.
- Do not carry out body side sectioning repairs in areas of door hinge or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision. Failure to follow these instructions may result in serious injury to vehicle occupant(s).
- Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury.
- All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision. Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash.
- If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash.

Engine Cooling System Health and Safety Precautions

WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.

Gasoline and Gasoline-Ethanol Fuel System Health and Safety Precautions

WARNING:
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
- Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.
- Avoid contact with fuel during a visual inspection for fuel leaks with the engine running. Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Diesel Fuel System Health and Safety Precautions

WARNING:
- Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury.
- Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Safety Belt and Supplemental Restraint System (SRS) Health and Safety Precautions

WARNING:
- Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment.
- Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury.
- Do not bleach or re-dye the safety belt webbing, as the webbing may weaken. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash.
- If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash.
- All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision. Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash.
- Anytime the Safety Canopy or side air curtain module has deployed, a new headliner and new A-, B-, C-, and/or D-pillar upper trim panels and attaching hardware must be installed. Make sure the headliner includes the word AIRBAG where it meets each B-pillar trim panel. Remove any other damaged components/hardware, and install new components/hardware as required. Always use new torque-prevailing type J-nuts when installing the Safety Canopy. Failure to follow these instructions may result in the Safety Canopy or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash.
- Do not repair or service restraint component connector terminals. If restraint connector terminals need repair, replace with the service connector pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle safety restraint, which increases the risk of serious personal injury or death in a crash.
- Never disassemble or tamper with seat belt deployable components, including pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors. Tampering or back probing may cause an accidental deployment and result in personal injury or death.
- Never tamper with, repair, or modify a Restraints Control Module (RCM) or any other Supplemental Restraint System (SRS) component. Failure to follow this instruction may result in incorrect operation of the Supplemental Restraint System (SRS), which increases the risk of serious personal injury or death in a crash.
- Never probe the electrical connectors on airbag, Safety Canopy(R) or side air curtain assemblies. Failure to follow this instruction may result in the accidental deployment of these assemblies, which increases the risk of serious personal injury or death.
- Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death.
- Do not obstruct or place objects in the deployment path of the Safety Canopy or side air curtain assembly. Never insert any type of fastener or tie strap around any portion of the Safety Canopy, side air curtain assembly, or related interior trim panel. Failure to follow this instruction may result in the Safety Canopy or side airbag curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash.
- Occupant Classification System (OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.
- Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification system (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash.
- Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash.
- Always carry or place a live Safety Canopy�, or side air curtain module, with the module and tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment.
- Always carry out the Zero Seat Weight Test whenever the passenger seat has been removed from the vehicle or any seat component has been removed from the seat. Never drive a vehicle with any seat components removed from an occupant classification system (OCS) equipped seat. Failure to follow these instructions may result in incorrect operation of the occupant classification system (OCS), which increases the risk of serious personal injury or death in a crash.
- Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash.

Wheel and Tire Health and Safety Precautions

WARNING:
- Never inflate a tire that has been run flat without first removing the tire from the wheel to inspect for damage. A damaged tire can fail during inflation. Failure to follow this instruction may result in serious personal injury.
- Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type wheels. Incorrect combinations could result in tire separation from wheel and may result in serious injury to vehicle occupant(s).
- Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of wheels from the vehicle. Failure to follow this instruction may result in serious personal injury.
- Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual rear wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
- Always match the tire size to the wheel size during assembly. Incorrect matching can result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may result in serious personal injury to technician or vehicle occupant(s).
- Do not weld or peen wheels. A wheel needing such repairs must have a new wheel installed. Failure to follow these instructions may result in wheel failure and serious personal injury.