Vehicle Damage Warnings
ELECTRICAL AND ELECTRONIC
^ Never disconnect the battery from the electrical system with the engine running.
^ Never connect or detach the ECU harness connector with the ignition switch ON.
^ Before performing electric welding procedures, unplug the ECU harness connector.
^ When painting, the following temperature limitations apply: Do not expose the ECU to temperatures above 95~C (203~F) except for brief periods. Do not expose the ECU to temperatures above 85~C (185~F) for longer than two hours.
^ Do not use a fast charger for engine starting. Disconnect the battery from the vehicle electrical system when fast charging the battery.
^ Do not hang the suspension components by the wheel speed sensor cables; these cables are delicate.
^ Do not hammer the wheel speed sensors into the front steering knuckles. The sensors are to be pushed in by hand only.
^ Take extreme care not to damage the tooth rings. Also, do not hammer the tooth rings, they must be pressed into hubs. Striking these can cause demagnetization or polarization, affecting the accuracy of the speed signal returning to the ABS control unit.
^ Each wheel speed sensor is labeled with a white tag which notes its proper location. The RH front, LH front, and rear wheel speed sensors are not interchangeable.
^ When servicing or replacing ABS components including the ECU, wheel sensors, hydraulic modulator, or wiring harness, verify proper ABS operation using approved procedures.
BRAKE SYSTEMS
^ Do not attempt to repair the hydraulic modulator. The only serviceable items on the modulator are the pump motor relay and solenoid relay.
^ Do not loosen any of the screws on the hydraulic modulator. After loosening, it is impossible to ensure that the wheel circuits are leak-free. The brake line fittings are the only threaded fasteners which can be removed from the hydraulic modulator.
^ Use care when handling brake fluid to avoid paint or plastic component damage.
^ Never use DOT 5 silicone brake fluids in the Bosch ABS 2 system; silicone brake fluid will seriously damage ABS hydraulic components.
^ When adding fluid to the Bosch ABS 2 anti-lock system, use only DOT 4 brake fluid from a clean, sealed container. Brake fluids meeting DOT 4 specifications are glycol-based. Glycol-type brake fluids are NOT compatible with silicone-based fluids. Do not use brake fluid from any container which is wet with water. The use of improper brake fluid, water contaminated, or mineral oil contaminated brake fluid will cause deterioration of rubber ABS components.
^ When draining fluid, do not empty expansion tank completely, so that no air can enter the brake system.
^ After performing work related to any ABS assembly, such as collision repair, verify proper ABS operation using approved procedures and the ABS test adapter.
^ Make absolutely sure the brake lines are properly routed after service.
NOTE: Always carefully note the routing, position, mounting and location of ABS wiring, connectors, clips, brackets, etc. Anti-lock components are extremely sensitive to EMI. Proper mounting is critical when servicing ABS components.
^ Remove the tire and wheel assemblies when replacing the front wheel speed sensors.
^ Coat the wheel speed sensors with an anticorrosion compound before installation. Do not use grease.
^ Pressure bleeding equipment must have a rubber diaphragm between the air supply and brake fluid. This will prevent outside air, moisture, oil, and other contaminants from entering the hydraulic brake system.