Vehicle Damage Warnings
ELECTRICAL AND ELECTRONIC SERVICETo avoid possible damage to electronic components, always follow testing procedures and observe the following precautions.
1. Discharge any static electrical charges before handling sensitive parts by touching ground or maintaining a ground connection to a bare skin area like the wrist, when servicing sensitive parts. [a]
2. Fully release electrical connector locks prior to disconnecting, and ensure connectors are fully seated with insulators and shields in place when reconnecting.
3. Never ground or apply full battery voltage to a component unless directed to do so in a test procedure. Directly grounding or applying battery voltage to a circuit could damage the Control Unit or system components.
4. When replacing electronic components, disconnect the battery ground.
NOTE: Before removing battery ground, access trouble codes. Control Unit memory will be erased if ground cable is removed.
5. Do NOT try to disassemble the control unit.
6. Never touch the Control Unit connector pins, integrated circuit connector pins, or soldered components on the Control Unit circuit board.
7. To prevent deforming control unit harness connectors, do not probe terminals directly. Instead, insert a pin from the harness side and perform measurements through pin.
8. When measuring voltage at the control unit harness connector, disconnect harness connector first, then turn ignition "ON" as necessary.
9. Use a digital multi-meter with a minimum 10 meg-ohms internal impedance when testing the Control Unit or related components, unless use of an analog meter is specified by the testing procedure. [b]
10. Use CAUTION NOT to create an arc while checking the continuity of a circuit.
11. Avoid getting water on any of the Fuel and Engine Control System Components.
12. Before performing electrical welding (for instance, spot welding), disconnect the climate control, injection, cruise control, Control Unit and radio.
13. In cases when temperatures may exceed 176°F (80°C), (example: infra-red spray booth), remove all Control Units.
14. Always verify that the battery is properly connected to the vehicle prior to starting the engine.
15. Do NOT disconnect the battery while the engine is running.
16. When charging a battery, be sure vehicle battery cables are disconnected.
17. The battery contains acid and produces explosive gas (hydrogen), avoid creating sparks near battery.
18. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically directed to do so in a test procedure.
19. In order to disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary leads to disable the ignition system.
20. Never pierce ignition leads or insulator boots to connect timing lights or analyzers. Use proper adapters.
21. When removing a spark plug wire twist the boot one quarter turn and pull on the boot only, never the lead itself.
22. Fuel and Engine Control System wiring should be at least 4 inches away from the high tension cables of the Ignition System, or be routed at a 90~ angle.
23. Never use a booster/starter which has a voltage rating above 12 volts to start engine.
[a] ELECTRICAL CHARGE AND DISCHARGE
Electronic components used in automotive computers are designed to operate at very low voltages (3-5V), and are extremely susceptible to damage caused by static electrical discharge. Voltages as low as 12 volts can damage computer circuits. By comparison, it takes as much as 4,000 volts of static discharge for a person to feel the "ZAP", and there is no way of knowing whether the charge is positive or negative in nature.
There are several ways in which a person can become statically charged. The most common methods of charging are by friction and induction. Friction between organic materials (such as cotton or leather) and synthetics (such as plastic, vinyl, or glass) will generate static charges as great as 25,000 volts. This can happen by simply sliding across a car seat or by wearing a cotton shirt under a coat made of synthetic materials. Charging by induction occurs when a person standing near a highly charged object (strong magnetic field such as a transformer) momentarily touches ground. Like charges are displaced to ground, leaving the person highly charged with opposite polarity. Static charges are gradually equalized by moisture in the air, but are retained much longer when humidity is low. Use care when handling and testing electronic components.
[b] PROPER TOOLS AND TESTING PROCEDURES
Use a digital multi-meter with a minimum 10 mega-ohms internal impedance when testing the Control Unit or related components, unless use of an analog meter is specified by the testing procedure. Do NOT use a self-powered test lamp to check for continuity. Analog meters have low internal impedance and cause circuit "loading" in low voltage circuits, resulting in inaccurate measurements and possible damage to components. Use of a multi-meter is necessary to obtain accurate measurements and avoid damaging low voltage Control Unit circuits and components.
FUEL SYSTEMS
1. Do not operate the fuel pump without fuel in the lines.
2. On fuel injected models do not depress the accelerator pedal while trying to start the car.
3. Handle all fuel injection related parts with care as they may easily be 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 equipped with catalytic converters, the following conditions must be observed:
a. Use only "UNLEADED FUEL".
b. Avoid running out of fuel.
c. In case of poor engine operation (misfiring), avoid driving the vehicle and correct the problem as soon as possible.
d. Do not disconnect a spark plug wire with the engine running.
e. Avoid push starting the vehicle.
f. If running on a dynamometer, make sure the catalytic converter is well ventilated.
g. Use caution when working near the catalytic converter to prevent the possibility of burns.
2. Do not use silicone based products on an oxygen sensor equipped vehicle to avoid damaging the sensor.
3. When performing a compression test, disconnect the ASD relay. (This will prevent the injectors from injecting any fuel into the cylinders, and will disable ignition).