Vehicle Damage Warnings

PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas before starting the work.

SPECIAL TOOLS
Use special tools when they are required.

NOTE: Mazda special service tools are specifically identified. If a Mazda special service tool is not suggested, please use an equivalent tool.

CAUTION: Start the engine only after making certain the engine compartment is clear of tools and people.

REMOVAL OF PARTS
While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair.

DISASSEMBLY
If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

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.

NOTE: Before removing battery ground, access Diagnostic Trouble Codes. Powertrain Control Module (PCM) memory is 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 12Volt 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 the control module.
19. Never use an auxiliary starting assist device which has a voltage rating above 12Volts.
20. When performing electric welding, disconnect electronic components such as climate control, injection, cruise control, PCM and radio.
21. In case of temperatures above 176°F (80°C), (example: infra-red spray booth), remove all PCMs.
22. Batteries produce explosive hydrogen gas. Avoid creating sparks near battery.


FUEL SYSTEMS
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.

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. When performing a compression test, remove fuel pump relay.