B
6
Repair and Service Manual
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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BEFORE SERVICING THE VEHICLE
Before attempting to inspect or service a vehicle, be
sure to read and understand the following warnings:
Before working on vehicle, remove all jewelry
(watches, rings, etc.).
Be sure that no loose clothing or hair can
become caught in the moving parts of the pow-
ertrain.
Use care not to contact hot objects.
Any servicing requiring adjustments to be
made to the powertrain while the motor is run-
ning must be made with drive wheels raised.
Wear OSHA approved clothing and eye pro-
tection when working on anything that could
expose the body or eyes to potential injury. In
particular, use care when working with or
around batteries, compressed air or solvents.
Always turn the key switch to ‘OFF’ and
remove key before disconnecting a live circuit.
When connecting battery cables, pay particular
attention to the polarity of the battery termi-
nals. Never confuse the positive and negative
cables.
The park brake should always be set, except
for cases where the powertrain must be
allowed to rotate or service is being performed
on the brake system.
If repairs are to be made that will require weld-
ing or cutting, the batteries must be removed.
Additional Warnings Specific to Electrical
System
Before working on the electrical system, be sure to read
and understand the following warnings that pertain to
electrical system repair or maintenance.
To prevent battery explosion that could result
in severe personal injury or death, keep all
smoking materials, open flame or sparks away
from the batteries.
Hydrogen gas is generated in the charging
cycle of batteries and is explosive in
concentrations as low as 4%. Because hydro-
gen gas is lighter than air, it will collect in the
ceiling of buildings necessitating proper venti-
lation. Five air exchanges per hour is consid-
ered the minimum requirement.
Be sure that the key switch is off and all elec-
trical accessories are turned off before starting
work on vehicle.
Remove batteries before performing any ser-
vices or repairs that could generate sparks.
Never disconnect a circuit under load at a bat-
tery terminal.
Since batteries are heavy,
use proper lifting tech-
niques when moving them.
Always lift battery with a
commercially available bat-
tery lifting device.
Use care not to tip batteries when removing or
installing; spilled electrolyte can cause burns
and damage.
The electrolyte in a storage battery is an acid
solution which can cause severe burns to the
skin and eyes. Treat all electrolyte spills to the
body and eyes with extended flushing with
clear water. Contact a physician immediately.
Wear eye protection when work-
ing on the vehicle. In particular,
use care when working around
batteries, or using solvents or
compressed air.
Any electrolyte spills should be neutralized
with a solution of 1/4 cup (60 ml) sodium bicar-
bonate (baking soda) dissolved in 1 1/2 gal-
lons (6 liters) of water and flushed with water.
Wrap wrenches with vinyl
tape to prevent the possibil-
ity of a dropped wrench
from ‘shorting out’ a bat-
tery, which could result in an explosion and
severe personal injury or death.
