General Precautions
ELECTRICAL AND ELECTRONIC
1. Ensure battery is properly connected prior to attempting to start engine.
2. Do not disconnect battery when engine is running.
3. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling.
4. Never connect or disconnect electrical connections with ignition "ON" unless specifically directed to do so in a test procedure.
5. To disable ignition system, unplug primary connections only. NEVER disconnect secondary leads to disable ignition system.
6. Do not use a self powered test lamp to check continuity.
7. Do not create arcing to check circuit continuity.
8. Disconnect cables when charging battery.
9. Disconnect the battery ground when replacing electronic components.
WARNING: Obtain audio anti-theft access code before disconnecting the battery cable.
NOTE: Before removing battery ground, access Diagnostic Trouble Codes. Control Module memory can be erased when ground cable is removed.
10. When measuring voltage at control module harness connector, disconnect harness connector first, then turn ignition "ON" as necessary.
11. To prevent deforming control module harness connectors, do not probe terminals directly. Insert a pin from harness side and perform measurements through pin.
12. Avoid getting water on fuel and 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 boot one quarter turn and pull on boot only, never the lead itself.
16. Always use 12 Volt battery as a power source.
17. Never apply battery power to a component unless told to do so in a test procedure.
18. Do not try to disassemble any control module.
19. Never use an auxiliary starting assist device which has a voltage rating above 12 Volts.
20. When performing electric welding, disconnect electronic components such as climate control, injection, cruise control, engine/transmission control modules and radio.
21. In case of temperatures above 80°C (176°F), (example: infra-red spray booth), remove all control modules.
22. Batteries produce explosive hydrogen gas. Avoid creating sparks near battery.
FUEL SYSTEMS
Fuel Pressure Release And Servicing Fuel System
WARNING: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this always complete the "Fuel Line Safety Procedures".
1. Do not operate fuel pump without fuel in lines and tank.
2. On fuel injected models, do not depress accelerator pedal while starting car.
3. Handle all fuel injection parts with care. Some components are easily 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.
NOTE: When pinching an air hose or a fuel hose with pliers, wrap the hose with a rag to prevent damage.
ENGINE AND EXHAUST
1. On vehicles with catalytic converters, observe these precautions:
a. Use only "UNLEADED FUEL".
b. Avoid running out of fuel.
c. In case of poor performance (such as misfiring), avoid driving and correct problems as soon as possible.
d. Do not disconnect spark plug wires with engine running.
e. Avoid push starting.
f. If running on a dynamometer, make sure catalytic converter is well ventilated.
g. To prevent burns, use caution when working near catalytic converters.
2. To avoid sensor damage, do not use silicone based products on an oxygen sensor equipped vehicle.
3. Disable fuel pump when performing a compression test.