Operation CHARM: Car repair manuals for everyone.

Vehicle Damage Warnings


WORKING WITH COMPUTER CONTROLLED EMISSION SYSTEMS
- Ensure battery is properly connected prior to attempting to start engine.
- Do not disconnect battery when engine is running.
- Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling.
- Never connect or disconnect electrical connections with ignition "On" unless specifically directed to do so in a test procedure.
- Do not use a self powered test lamp to check continuity.
- Do not create arcing to check circuit continuity.
- Disconnect the battery ground when replacing electronic components.

NOTE: Before removing battery ground, access Diagnostic Trouble Codes (DTC)s. Powertrain Control Module (PCM) memory is erased when ground cable is removed.

- When measuring voltage at control module harness connector, disconnect harness connector first, then turn ignition "On" as necessary.
- To prevent deforming control module harness connectors, do not probe terminals directly. Insert a pin from harness side or use a "Break Out Box" to perform pin measurements.
- Avoid getting water on fuel and engine control system components.
- Fuel and engine control system wiring should be at least 4 inches away from high tension cables.
- Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters.
- Always use 12 Volt battery as a power source.
- Never apply battery power to a component unless told to do so in a test procedure.
- Do not try to disassemble the PCM.
- Never use an auxiliary starting assist device which has a voltage rating above 12 Volts.

FUEL SYSTEMS
- Do not operate fuel pump without fuel in lines and tank.
- On fuel injected models, do not depress accelerator pedal while starting car.
- Handle all fuel injection parts with care. Some components are easily damaged.
- Always use new gaskets or O-rings when installing fuel lines or injectors.
- Lightly lubricate O-rings and flare connections with gasoline. Do not use engine oil, gear lubricant or brake fluid.
- After servicing fuel system, check for leaks and correct as needed.

ENGINE AND EXHAUST
- On vehicles with catalytic converters, observe these precautions:
- Use only "UNLEADED FUEL".
- Avoid running out of fuel.
- In case of poor performance (such as misfiring), avoid driving and correct problems as soon as possible.
- Do not disconnect spark plug wires with engine running.
- Avoid push starting.
- If running on a dynamometer, make sure catalytic converter is well ventilated.
- To prevent burns, use caution when working near catalytic converters.
- To avoid Heated Oxygen Sensor (HO2S) damage, do not use silicone based products on an HO2S equipped vehicle.
- When performing a compression test, remove fuel pump relay or disable injection system as prescribed by manufacturer.