Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component movements can be rotational or 1-3 dimensional movements.
Scheme 1
Scheme 1: Movement Symbols
| Item | Description |
|---|
| 1 | Minor component movement clockwise/counterclockwise |
| 2 | Major component movement clockwise/counterclockwise |
| 3 | Component movement to the left/right/up/down |
| 4 | Component movement towards/away |
| 5 | 3 dimensional component movement |
| 6 | 2 dimensional component movement |
| 7 | 3 dimensional component rotation |
| 8 | 3 dimensional component cycling |
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
Scheme 2
| Item | Description |
|---|
| 1 | Turn the component clockwise through 45° |
| 2 | Turn the component counterclockwise through 45° |
| 3 | Turn the component clockwise through 90° |
| 4 | Turn the component counterclockwise through 90° |
| 5 | Turn the component clockwise through 180° |
| 6 | Turn the component counterclockwise through 180° |
| 7 | Turn the component clockwise through 2 complete turns |
| 8 | Turn the component counterclockwise through 2 complete turns |
Steering Wheel Symbols
Steering wheel symbols are used to provide further information to a required steering wheel position or steering column lock status.
Scheme 3
Scheme 3: Steering Wheel Symbols
| Item | Description |
|---|
| 1 | Steering wheel in straight ahead position |
| 2 | Steering column lock locked |
| 3 | Steering column lock unlocked |
| 4 | Turn the steering wheel to the 90° left position |
| 5 | Turn the steering wheel to the 90° right position |
| 6 | Turn the steering wheel to the left-hand end position |
| 7 | Turn the steering wheel to the right-hand end position |
Body Types
Body type symbols are used to identify different body configurations.
Scheme 4
| Item | Description |
|---|
| 1 | 3, 4, 5-door body style |
| 2 | Wagon body style |
| 3 | Sport utility vehicle body style |
| 4 | Coupe body style |
| 5 | Convertible body style |
| 6 | Van body style |
| 7 | 3, 4, 5-door body style - Top View |
| 8 | Wagon body style - Top View |
| 9 | Underbody view |
| 10 | Right-hand drive (RHD) vehicle |
| 11 | Left-hand drive (LHD) vehicle |
Gearshift lever and selector lever position symbols
Gearshift lever and selector lever position symbols are used to show the lever position that is required to be selected to carry out a procedure step.
Scheme 5
Scheme 5: Gearshift lever and selector lever position symbols
| Item | Description |
|---|
| 1 | Replaced by symbol 9 |
| 2 | Replaced by symbol 10 |
| 3 | Replaced by symbol 11 |
| 4 | Replaced by symbol 12 |
| 5 | Replaced by symbol 12 |
| 6 | Replaced by symbol 14 |
| 7 | Replaced by symbol 15 |
| 8 | Replaced by symbol 16 |
| 9 | Set the selector lever to the park (P) position |
| 10 | Set the selector lever to the reverse (R) position |
| 11 | Set the selector lever to the neutral (N) position |
| 12 | Set the selector lever to the drive (D) position |
| 13 | Set the selector lever to the drive (S) position |
| 14 | Set the selector lever to the drive (M) position |
| 15 | Set the selector lever to the drive (-) position |
| 16 | Set the selector lever to the drive (+) position |
| 17 | Set the gearshift lever to the neutral (N) position |
| 18 | Further gearshift lever positions that may appear in Illustrations |
Screwdriver symbols
The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure step.
Scheme 6
Scheme 6: Screwdriver symbols
| Item | Description |
|---|
| 1 | Screwdriver |
| 2 | Cross bladed screwdriver |
| 3 | Flat-bladed screwdriver |
| 4 | Hexagonal screwdriver |
| 5 | TORX screwdriver |
Pliers Symbols
The plier symbols are used to show which pliers is recommended to carry out a procedure step.
Scheme 7
| Item | Description |
|---|
| 1 | Combination pliers |
| 2 | Side cutter pliers |
| 3 | Securing ring - inner |
| 4 | Securing ring - outer |
| 5 | Hose clamp pliers |
| 6 | Locking pliers |
| 7 | Long nose pliers |
Drill Symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry out a procedure step.
Scheme 8
| Item | Description |
|---|
| 1 | Drill bit with a specified diameter |
| 2 | Hole saw with a specified diameter |
| 3 | Stepped drill bit with a specified diameter |
| 4 | Tap with a specified diameter |
| 5 | Die with a specified diameter |
| 6 | Scraper for circular holes |
| 7 | Scraper for straight edges |
Cutting Tool Symbols
The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure step.
Scheme 9
Scheme 9: Cutting Tool Symbols
| Item | Description |
|---|
| 1 | Cutting knife |
| 2 | Air body saw |
| 3 | Scissors |
| 4 | Grinder |
| 5 | Jig saw |
| 6 | Plasma cutter |
| 7 | Sanding Paper |
| 8 | Wire brush |
Apply Chemical or load symbols
The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry out a procedure step.
Scheme 10
Scheme 10: Apply Chemical or load symbols
| Item | Description |
|---|
| 1 | Apply the substance from the specified tube |
| 2 | Apply the substance from the specified cartridge |
| 3 | Apply the specified chemical with a brush |
| 4 | Apply the specified load to the specified component |
| 5 | Apply a bead with a specific diameter from the specified tube |
| 6 | Apply a bead with a specific diameter from the specified cartridge |
| 7 | Apply the specified chemical with a roller |
| 8 | Apply hot glue to the specified component |
| 9 | Apply the specified amount of fluid from the fluid can |
| 10 | Apply fluid from the fluid can |
| 11 | Clean the specified component with the specified material |
| 12 | Apply a broken bead from the specified tube |
| 13 | Apply the specified chemical from a spray can |
| 14 | Apply the specified lubricant to the specified component |
| 15 | Apply spot welds to the specified component |
| 16 | Apply a continuous weld to the specified component |
| 17 | Handle the fluid using a syringe |
| 18 | Extract the specified amount of fluid using a syringe |
Measurement Symbols
The measurement symbols are used to show where to measure which type of measurement to carry out a procedure step.
Scheme 11
Scheme 11: Measurement Symbols
| Item | Description |
|---|
| 1 | Measure the current using a digital multimeter |
| 2 | Measure the voltage using a digital multimeter |
| 3 | Measure the resistance using a digital multimeter |
| 4 | Measure the length/distance |
| 5 | Check that the specified pressure is available using a suitable pressure gauge |
| 6 | Measure the pressure at the specified port using a suitable pressure gauge |
| 7 | Measure the time using a suitable stopwatch |
| 8 | Wait for the specified period of time |
| 9 | The specified task requires the specified minimum temperature |
| 10 | The specified task requires the specified maximum temperature not to be exceeded |
| 11 | The specified task requires the specified temperature range |
| 12 | The specified task requires the specified temperature |
| 13 | Measure and check for the specified value using a dial indicator gauge |
| 14 | Measure and check for the specified MAX value using a dial indicator gauge |
| 15 | Measure and check for the specified MIN value using a dial indicator gauge |
General equipment symbols
The general equipment symbols are used to show where to use which type of general equipment to carry out a procedure step.
Scheme 12
Scheme 12: General equipment symbols
| Item | Description |
|---|
| 1 | Hot air gun |
| 2 | Soldering iron |
| 3 | Scraper |
| 4 | Scriber |
| 5 | Securing strap |
| 6 | File with specified size |
| 7 | Center punch |
| 8 | Marker |
| 9 | Mallet |
| 10 | Hose clamp |
| 11 | Interior trim remover |
| 12 | Vacuum cleaner |
| 13 | Strap wrench |
| 14 | Wedge |
| 15 | Pin punch |
| 16 | Air blow gun |
| 17 | Relocate and support the component |
Welding Symbols
These symbols indicate the type of welding to be used.
Scheme 13
Scheme 13: Welding Symbols
| Item | Description |
|---|
| 1 | Metal inert gas (MIG) / Metal active gas (MAG) welding equipment |
| 2 | Metal inert gas (MIG) welding equipment |
| 3 | Metal inert gas (MIG) brazing equipment |
| 4 | Apply a continuous weld to the specified component |
| 5 | Apply spot welds to the specified component |
| 6 | C-clamp |
Drilling and grinding symbols
These symbols indicate the type of drilling or grinding to be used.
Scheme 14
Scheme 14: Drilling and grinding symbols
| Item | Description |
|---|
| 1 | Drill through first body layer with a suitable diameter |
| 2 | Drill through first body layer with the specified diameter |
| 3 | Drill through the indicated number of body layers with a suitable diameter |
| 4 | Drill through the indicated number of body layers with the specified diameter |
| 5 | Drill through the indicated number of body layers with a suitable diameter |
| 6 | Drill through the indicated number of body layers with the specified diameter |
| 7 | Drill through all body layers with a suitable diameter |
| 8 | Drill through all body layers with the specified diameter |
| 9 | Grind one layer |
| 10 | Grind two layers |
| 11 | Grind to last layer |
| 12 | Grind all layers |
| 13 | Material thickness > Xmm |
Material Symbols
The material symbols are used to show where to use which type of material to carry out a procedure step.
Scheme 15
Scheme 15: Material Symbols
| Item | Description |
|---|
| 1 | Remove/Install the specified blind rivet |
| 2 | Apply tape to the specified component/area |
| 3 | Remove/Install the specified cable tie |
Miscellaneous Symbols
These symbols provide further information that is required to carry out a procedure step.
Scheme 16
Scheme 16: Miscellaneous Symbols
| Item | Description |
|---|
| 1 | Set the ignition switch to the 0 position |
| 2 | Set the ignition switch to the II position |
| 3 | The procedure step requires the aid of the specified number of supporting technicians |
| 4 | Self contained breathing apparatus |
| 5 | General prohibition used in combination with another symbol |
| 6 | Do not use power tools |
| 7 | Visual check |
| 8 | Noise check |
| 9 | Dispose the specified component |
| 10 | Replaced by item 9 (Dispose the specified component) |
| 11 | Set the engine speed to the specified value |
| 12 | Fully apply the parking brake lever |
| 13 | Fully release the parking brake lever |
| 14 | Do not dispose of batteries into the waste bin |
| 15 | Visual check using a mirror |
| 16 | Area/component must be dry |
Mandatory Protective Equipment - Health and safety symbols
The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce possible health and safety risks.
Scheme 17
Scheme 17: Mandatory Protective Equipment - Health and safety symbols
| Item | Description |
|---|
| 1 | Wear protective gloves |
| 2 | Wear face guard |
| 3 | Wear safety goggles |
| 4 | Wear ear protectors |
| 5 | Wear safety goggles and ear protectors |
| 6 | Wear a respirator |
Prohibition - Health and safety symbols and component damage
The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible component damage and health and safety risks.
Scheme 18
Scheme 18: Prohibition - Health and safety symbols and component damage
| Item | Description |
|---|
| 1 | General Prohibition symbol |
| 2 | No naked flames |
| 3 | No smoking |
| 4 | No water |
| 5 | Do not touch |
| 6 | Do not switch |
| 7 | No grinding |
Warning Symbols - Health and Safety Warnings and Component damage
The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible component damage and health and safety risks.
Scheme 19
Scheme 19: Warning Symbols - Health and Safety Warnings and Component damage
| Item | Description |
|---|
| 1 | Hazardous voltage/Electrical shock/Electrocution |
| 2 | Fire hazard/Highly flammable |
| 3 | Burn hazard/Hot surface |
| 4 | Automatic start-up |
| 5 | Toxic |
| 6 | Explosive material |
| 7 | Battery hazard |
| 8 | Corrosive material |
| 9 | Lifting hazard |
| 10 | Hand crush/Force from above |
| 11 | Cutting of fingers or hand |
| 12 | Pressure hazard |
| 13 | Invisible laser radiation. Do not view directly with optical instruments (magnifiers). Class 1M laser product |
Control Diagram symbols - Description and Operation procedures
These symbols provide further information on the type of connectivity, direction of flow or type of data bus of a system.
Scheme 20
Scheme 20: Control Diagram symbols - Description and Operation procedures
| Item | Description |
|---|
| 1 | Medium Speed Controller Area Network |
| 2 | High Speed Controller Area Network |
| 3 | Local Interconnect Network |
| 4 | Wires cross but are not connected |
This information describes and directs repair procedures for this vehicle model year. It includes diagnostics for all vehicle systems except driveability and emission control. Refer to the appropriate information on separate Powertrain Control/Emissions Diagnosis (PC/ED) information for driveability and emission control diagnostics.
Information is organized into groups, with sections that have subsections dividing them.
Warnings, Notices, and Notes in This Information
Warnings provide information to avoid personal injury and to make sure service actions on critical safety systems are performed correctly.
Notices provide information to avoid damage to the vehicle or a component.
Notes provide information critical for a complete and effective repair.
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the procedure.
Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step. Those that apply to an information of steps will be placed at the first step requiring it.
Vehicle and Engine Orientation Identifiers
LH and RH vehicle designations are oriented from the driver's seat position looking forward. LH and RH engine designations are oriented from the flywheel position looking towards the crankshaft pulley.
DTC and Symptom Charts
Module DTC Charts are used to begin and direct the diagnosis of a DTC. Symptom Charts contain concern symptoms and direct solutions either in the chart or in a linked Diagnostic Routine. Both DTC and Symptom Charts may provide the solution within the chart, or provide a link to the appropriate Diagnostic Routine.
In some sections, the Symptom Chart is preceded by a Preliminary Inspection which must be followed prior to using the Symptom Chart
Using Module DTC Charts
This Workshop information contains diagnostics for DTCs set by vehicle modules. Driveability and emission DTCs are covered in the separate Powertrain Control/Emissions Diagnosis (PC/ED) information. If a PCM-set DTC is not listed in the Workshop information, it is serviced in the Powertrain Control/Emissions Diagnosis (PC/ED) information.
DTC diagnostics are found in both on-line and printed publications and are used as follows
- On-line publications: Using the left side menu, click on the Master DTC Chart link to view the vehicle module DTC charts. Each module has a chart with links or in-chart solutions for all DTCs diagnosed in the Workshop information.
- Printed publications: Use the DTC index in the rear of the book.
Diagnostic Methods
Diagnostic Methods provides information to support diagnosing Ford vehicles. Diagnostic strategies, diagnostic tool support information, and advanced circuit testing methods are included. REFER to DIAGNOSTIC METHODS -- GASOLINE MODELS .
Diagnostic Routines
Diagnostic Routines provide information to determine the root cause of concerns addressed in either a DTC Chart or Symptom Chart. Each Diagnostic Routine contains
- Diagnostic Overview Wiring Diagram References (as applicable) Normal Operation and Fault Conditions Visual Inspection and Diagnostic Pre-checks
- Tool Table (as applicable)
- Material Table (as applicable)
- Pinpoint Test Steps
Component Tests
Component Tests are used to separately analyze a single common component in a system. The test will determine if the part is functioning correctly.
Reuse Of Fasteners, Seals, Or Gaskets
The following is a list of assumptions made in the reuse of fasteners, seals, or gaskets.
- Seals and gaskets must be replaced unless otherwise specified.
- Standard fasteners are reused unless otherwise specified.
- Fasteners with self-locking features must be replaced unless otherwise noted. Reminder text may or may not be included with the procedure step. Examples of fastener coatings or fasteners with mechanical locking (with the locking features highlighted yellow) are shown in illustration 1.
- Torque to yield bolts (bolts with more than one stage of tightening torque and a final torque angle specification) must be discarded and new torque to yield bolts installed unless otherwise stated within the procedure.
Scheme 21
Scheme 21: Illustration 1 - self-locking coatings or locking feature are highlighted yellow
Graphics
Illustrations in this information may be used to replace written step instructions. Color-coding (see color scheme in this information) is used to communicate the required step action or actions. Service action icons (see SYMBOLS GLOSSARY ) are used to add additional information regarding the required action.
- The color scheme in a step graphic (an illustration used in removal or installation steps) indicates servicing information as follows: Fasteners (including panel retainers) or electrical connectors - Magenta (Purple) Target component that is to be removed - Blue Components that must be removed prior to the target component shown in illustration in blue - Brown or Green Components placed aside for access, but not removed; highlighted areas such as inspection areas, adjustments or measurements - Yellow Essential Special Service Tools (ESSTs) and other tools - Pale Blue Chemical or Sealer apply areas - Alternating blue and white dashes (see «Illustration 4»(/ford/econoline-e250/2012-2013/remont/oem-general-information/#service-information-introduction) ) Sectioned or cut-away areas - Red Remaining components - Grey
Callouts in graphics indicate removal (or tightening) order, or identify individual instructions in substeps of the same number (such as different torque values).
Arrows containing x numbers (Illustration 2) indicate the number of identical fasteners or connectors to be removed or installed in the graphic.
In Illustration 2, two identical fasteners are indicated by the x2 arrow, with another arrow illustrating a third fastener of a different type. Because the different fasteners require different torques, callouts are used to identify those two torque values in the associated step text. The hose clamp is another fastener to be removed. The yellow coloring of the hose indicates it is to be moved aside (not removed).
The following written steps would be necessary if the illustration did not have color coding
- Remove the engine oil pipe fastener at the engine connection.
- Remove the two engine oil pipe fasteners from the turbocharger and remove the pipe.
- Remove the air inlet hose from the turbocharger and position aside.
Scheme 22
Scheme 22: Illustration 2
Hidden fasteners, such as panel retainers, are identified in the illustration by a magenta disc. An inset detail view illustrating the fastener type may be included (Illustration 3).
Scheme 23
Scheme 23: Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward
Symbols
Symbols may be used inside graphics or in the text area to communicate service actions. The following examples demonstrate the use of some of these symbols. REFER to SYMBOLS GLOSSARY for a complete symbols list with explanations.
In the Illustration 4 example, service action symbols are shown as used to direct the application of sealer, lubricant, weight, tape or cleaning detergent to a component. In this example a bead diameter of "xx" millimeters is prescribed. The blue and white dashes indicate where the material is applied.
Scheme 24
Scheme 24: Illustration 4
Illustration 5 is an example of location symbols used to show the location of a component or system within the vehicle.
Scheme 25
Scheme 25: Illustration 5
Illustration 6 shows how gearshift lever or selector lever position symbols may be used to indicate the gearshift lever or selector lever position required. The required Essential Special Service Tool to align the shift mechanism is shown in illustration in pale blue and identified by ESST number.
Scheme 26
Scheme 26: Illustration 6
Callouts or arrows may be used to identify components for supporting special information, such as a required sequence or to indicate a number of identical components. Illustration 7 shows a removal order in the top graphic and the bottom graphic indicates 12 identical bolts.
Scheme 27
Scheme 27: Illustration 7
Standard tool symbols direct the use of standard tools to perform a service action, such as the cutting of carpet shown in Illustration 8. Tool symbols may include dimensional values (for example, a drill with a specified diameter).
Scheme 28
Scheme 28: Illustration 8
Safety Warnings
Review carefully the General Service Health and Safety Precautions below before beginning any repair. Following these general service warnings are specific system warnings that must be carefully reviewed before beginning work on any listed system.
General Service Health and Safety Precautions
| WARNING | Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate during operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and replace with a new fan as necessary. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Vehicles with engine auto start-stop technology may start automatically with the ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating engine parts. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the vehicle weight, including any vehicle cargo or modifications. Always position the hoist lift arms as shown in the illustration. Do not use the engine to power the drive wheels unless all drive wheels are elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with the ground can cause unintended vehicle movement. Failure to follow these instructions may result in serious personal injury or death. |
| WARNING | Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the vehicle weight, including any vehicle cargo or modifications. Identify the correct jacking points as shown in the illustration. Position the vehicle on a hard, level surface. After jacking, always support vehicle with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake and block all wheels remaining on the ground. Failure to follow these instructions may result in unintended vehicle movement and serious personal injury or death. |
| WARNING | Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Never support an engine by the intake or exhaust manifolds. The engine may drop suddenly. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Disconnect the window regulator motor connector before working inside the vehicle doors. Service actions inside the door (such as door latch, handle or lock cylinder service) or operating the remote keyless entry (RKE) fob may activate the windows on vehicles equipped with global open/close. Serious injury to hands or arms may occur if a window motor is activated during service. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Keep solvents away from ignition sources. Solvents may be flammable and can ignite or explode if not handled correctly. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Use only a type-D fire extinguisher to extinguish magnesium fires. Never attempt to use a type-A, -B, -C extinguisher, or water, as these items are ineffective and may accelerate a magnesium fire. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with obstructions may cause the assembly to fall off the jack, which could result in serious personal injury. |
| WARNING | Always verify that the lockpin on a bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Carefully read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when removing fasteners. Failure to follow this instruction may result in injured fingers. |
Carefully review the following system safety warnings before beginning any service or repair work.
High Voltage System Health and Safety Precautions
| WARNING | To prevent the risk of high-voltage shock, always follow precisely all warnings and service instructions, including instructions to depower the system. The high-voltage system utilizes approximately 300 volts DC, provided through high-voltage cables to its components and modules. The high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All high-voltage components are marked with high-voltage warning labels with a high-voltage symbol. Failure to follow these instructions may result in serious personal injury or death. |
| WARNING | Never install the service disconnect plug when a high-voltage service cover is removed. Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent contact with the high voltage which is present at several points under the cover. Failure to follow these instructions may result in serious personal injury or death. |
| WARNING | Turn OFF the ignition switch for a minimum of 5 minutes before removing high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious personal injury or death. |
Climate Control System Health and Safety Precautions
| WARNING | Air conditioning R-134a liquid refrigerant is capable of harming eyes or freezing skin. Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Air conditioning R-134a refrigerant gas is capable of displacing the air necessary for breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not release a large quantity of R-134a gas within a confined space or allow it to be exposed to a high temperature flame (such as a torch). Consult the Material Safety Data Sheet for further information. Failure to follow these instructions may result in serious personal injury or death. |
| WARNING | Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Before disconnecting any heater water hoses, shut OFF the engine and wait until engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot liquid escaping from the engine cooling system. |
| WARNING | The electric booster heater may become hot during use and can burn unprotected skin. Allow enough time for the heater to cool before servicing. Failure to follow this instruction may result in serious personal injury. |
Battery and Battery Charging System Health and Safety Precautions
| WARNING | Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery. |
| WARNING | Battery posts, terminals and related accessories contain lead and lead components. Wash hands after handling. Failure to follow these instructions may result in serious personal injury. |
Brake System Health and Safety Precautions
| WARNING | Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. |
| WARNING | Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury. |
Body Repair Health and Safety and General Precautions
| WARNING | Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear protective equipment as directed. Examples may include but are not limited to respirators and chemically resistant gloves. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always wear protective equipment including eye protection with side shields, and a dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not carry out body side sectioning repairs in areas of door hinge or striker anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise structural integrity during a collision. Failure to follow these instructions may result in serious injury to vehicle occupant(s). |
| WARNING | Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing adequate visibility are recommended. It is strongly recommended that persons working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may result in serious personal injury. |
| WARNING | All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision found in SAFETY BELT SYSTEM General Procedures of this information. Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash. |
| WARNING | If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. |
Engine Cooling System Health and Safety Precautions
| WARNING | Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. |
Gasoline and Gasoline-Ethanol Fuel System Health and Safety Precautions
| WARNING | Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. |
| WARNING | When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Avoid contact with fuel during a visual inspection for fuel leaks with the engine running. Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury. |
Diesel Fuel System Health and Safety Precautions
| WARNING | Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury. |
Safety Belt and Supplemental Restraint System (SRS) Health and Safety Precautions
| WARNING | Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. |
| WARNING | Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) away to make sure of personal safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is required. Failure to follow these instructions may result in serious personal injury. |
| WARNING | Do not bleach or re-dye the safety belt webbing, as the webbing may weaken. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. |
| WARNING | If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. |
| WARNING | All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision found in SAFETY BELT SYSTEM General Procedures of this information. Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash. |
| WARNING | Anytime the Safety Canopy or side air curtain module has deployed, a new headliner and new A-, B-, C-, and/or D-pillar upper trim panels and attaching hardware must be installed. Make sure the headliner includes the word AIRBAG where it meets each B-pillar trim panel. Remove any other damaged components/hardware, and install new components/hardware as required. Always use new torque-prevailing type J-nuts when installing the Safety Canopy. Failure to follow these instructions may result in the Safety Canopy or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. |
| WARNING | Do not repair or service restraint component connector terminals. If restraint connector terminals need repair, replace with the service connector pigtails. Failure to follow this instruction may result in incorrect operation of the vehicle safety restraint, which increases the risk of serious personal injury or death in a crash. |
| WARNING | Never disassemble or tamper with seat belt deployable components, including pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors. Tampering or back probing may cause an accidental deployment and result in personal injury or death. |
| WARNING | Never tamper with, repair, or modify a Restraints Control Module (RCM) or any other Supplemental Restraint System (SRS) component. Failure to follow this instruction may result in incorrect operation of the Supplemental Restraint System (SRS), which increases the risk of serious personal injury or death in a crash. |
| WARNING | Never probe the electrical connectors on airbag, Safety Canopy® or side air curtain assemblies. Failure to follow this instruction may result in the accidental deployment of these assemblies, which increases the risk of serious personal injury or death. |
| WARNING | Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy® and cause serious personal injury or death. |
| WARNING | Do not obstruct or place objects in the deployment path of the Safety Canopy or side air curtain assembly. Never insert any type of fastener or tie strap around any portion of the Safety Canopy, side air curtain assembly, or related interior trim panel. Failure to follow this instruction may result in the Safety Canopy or side airbag curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. |
| WARNING | Occupant Classification System (OCS) parts are calibrated as an assembly and must only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash. |
| WARNING | Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification system (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a crash. |
| WARNING | Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. |
| WARNING | Always carry or place a live Safety Canopy®, or side air curtain module, with the module and tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment. |
| WARNING | Always carry out the Zero Seat Weight Test whenever the passenger seat has been removed from the vehicle or any seat component has been removed from the seat. Never drive a vehicle with any seat components removed from an occupant classification system (OCS) equipped seat. Failure to follow these instructions may result in incorrect operation of the occupant classification system (OCS), which increases the risk of serious personal injury or death in a crash. |
| WARNING | Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. |
Wheel and Tire Health and Safety Precautions
| WARNING | Never inflate a tire that has been run flat without first removing the tire from the wheel to inspect for damage. A damaged tire can fail during inflation. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type wheels. Incorrect combinations could result in tire separation from wheel and may result in serious injury to vehicle occupant(s). |
| WARNING | Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of wheels from the vehicle. Failure to follow this instruction may result in serious personal injury. |
| WARNING | Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual rear wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious injury to vehicle occupant(s). |
| WARNING | Always match the tire size to the wheel size during assembly. Incorrect matching can result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may result in serious personal injury to technician or vehicle occupant(s). |
| WARNING | Do not weld or peen wheels. A wheel needing such repairs must have a new wheel installed. Failure to follow these instructions may result in wheel failure and serious personal injury. |
