Vehicle Damage Warnings

ELECTRICAL PRECAUTIONS

The following guidelines are intended to ensure the safety of the operator whilst preventing damage to the electrical and electronic components fitted to the vehicle. Where necessary, specific precautions are detailed in the relevant sections of this document, reference of which should be made prior to commencing repair operations.

Equipment - Prior to commencing any test procedure on the vehicle, ensure that the relevant test equipment is working correctly and any harness or connections are in good condition. This particularly applies to mains lead or connections.

WARNING: Before commencing work on an ignition system, all high tension terminals, adaptors and diagnostic equipment for testing should be inspected to ensure that they are adequately insulated and shielded to prevent accidental personal contact and to minimize the risk of shock. Wearers of surgically implanted pacemaker devices should not work in close proximity to ignition circuits or diagnostic equipment.

Polarity - Never reverse connect the vehicle battery and always observe correct polarity when connecting test equipment.

High Voltage Circuits - Whenever disconnecting live ht circuits, always use insulated pliers and never allow the open end of the ht lead to come into contact with other components, particularly ECU's. Since high voltage spikes can occur on the terminals of the coil while the engine is running, exercise caution when measuring the voltage at these points.

Connectors and Harnesses - The engine compartment of a vehicle is a particularly hostile environment for electrical components and connectors. Always ensure these items are dry and oil free before disconnecting and connecting test equipment. Never force connectors apart either by using tools or by pulling on the wiring harness. Always ensure locking tabs are disengaged before removal and note orientation to enable correct reconnection. Ensure that any protective covers and substances are replaced if disturbed.

Before removing a faulty component, refer to the Workshop Manual for removal procedures. Ensure the ignition switch is turned to the 'OFF' position, the battery is disconnected (see Battery Disconnecting ) and any disconnected harnesses are supported to avoid any undue strain at the terminals. When replacing the component keep oily hands away from electrical connection areas and push connectors home until any locking tabs fully engage.

Battery Disconnecting
Before disconnecting the battery, switch off all electrical equipment. If the radio is to be serviced, ensure the security code has been deactivated. When the battery is disconnected, certain data such as radio code and clock time will be lost.

CAUTION: To prevent damage to electrical components, ALWAYS disconnect the battery when working on the vehicle electrical systems. The earth lead must be disconnected first and reconnected last. Always ensure that battery leads are routed correctly and are not close to any potential chafing points.

Battery Charging
Recharge the battery out of the vehicle and keep the top well ventilated. While being charged or discharged, and for approximately fifteen minutes afterwards, batteries emit hydrogen gas. This gas is inflammable.

Always ensure any battery charging area is well ventilated and that every precaution is taken to avoid flames and sparks.

Disciplines
Switch off ignition prior to making any connection or disconnection in the system as electrical surge caused by disconnecting 'live' connections can damage electrical components.

Ensure hands and work surfaces are clean and free of grease, swarf, etc. as grease collects dirt which can cause tracking or high-resistance contacts.

When handling printed circuit boards, treat them as you would a disc hold by the edges only; note that some electrical components are susceptible to body static.

Connectors should never be subjected to forced removal or refit, especially inter-board connectors. Damaged contacts will cause short-circuit and open-circuit conditions.

Prior to commencing testing, and periodically during testing, touch a good earth, i.e. cigar lighter socket, to discharge body static as some electrical components are vulnerable to static electricity.

Grease for Electrical Connectors
Some under bonnet and under body connectors are protected against corrosion by the application of a special grease during production. Should connectors of this type be disturbed, repaired, or replaced, a grease of this type, available under part number BAU 5811, should again be applied. Do not apply grease to any connectors that do not have grease applied as standard.

NOTE: The use of other greases must be avoided as they can migrate into relays, switches, etc. contaminating the contacts and leading to intermittent operation or failure.