Operation CHARM: Car repair manuals for everyone.

Vehicle Damage Warnings

ELECTRICAL AND ELECTRONIC


1. Fully release connector locks prior to disconnecting. Ensure connectors are fully seated and all insulators and shields are in place when reinstalling.
2. Never connect or disconnect electrical connections with the ignition switch in the "ON" position unless specifically instructed to do so in a test procedure.
3. To disable the ignition system, unplug the primary connections only. NEVER disconnect the secondary (high-tension) leads to disable the ignition system.
4. Disconnect the battery ground before replacing any electronic components.
5. When measuring voltage at the control unit harness connector, turn off ignition first, disconnect harness, then turn ignition on to measure voltage.
6. Take all electrical measurements from the back side of the harness connector. Do NOT probe the harness from the connector side. Failure to observe this precaution may result in deformed connectors.
7. Avoid getting water on any fuel or engine control system 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 engine.
3. Handle all fuel injection parts with care. They are easily damaged and may be ruined if contaminated.
4. Always use new gaskets and O-rings when reinstalling injectors and fuel system components.
5. Lightly lubricate O-rings and flare connections with fuel. Do NOT use engine oil, gear lubricant, or brake fluid.
6. After servicing the fuel system, ALWAYS check for leaks and correct as necessary.

ENGINE AND EXHAUST
1. On vehicles equipped with catalytic converters, the following precautions must be observed:
a. Use "UNLEADED" fuel only.
b. Avoid running out of fuel
c. In case of poor engine operation (i.e., misfiring), avoid driving the vehicle and correct the problem as soon as possible.
d. Do not disconnect a spark plug wire while the engine is 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 oxygen-sensor equipped vehicles to avoid contaminating the sensor.
3. When performing a compression test, remove the fuel pump relay to prevent injector operation.