To prevent damage to the on-board computer, alternator and regulator, the following precautionary measures must be taken when working with the electrical system.
Wear safety glasses when working on or near the battery.
Don't wear a watch with a metal band when servicing the battery. Serious burns can result if the band completes the circuit between the positive battery terminal and ground.
When installing a battery, make sure that the positive and negative cables are not reversed.
Be absolutely sure of the polarity of a booster battery before making connections. Connect the cables positive-to-positive, and negative-to-negative. Connect positive cables first and then make the last connection to ground on the body of the booster vehicle, so that arcing cannot ignite hydrogen gas that may have accumulated near the battery.
Even momentary connection of a booster battery with the polarity reversed will destroy the alternator.
Disconnect both battery cables -negative first -before attempting to charge a battery.
NEVER ground the alternator output cable.
Be cautious when using metal tools around a battery to avoid creating a short circuit between the terminals.
NEVER ground the field circuit between the alternator and regulator.
NEVER attempt to polarize an alternator.
NEVER operate the alternator with the battery disconnected.
Do NOT short across or ground any alternator terminals.
Do NOT apply full battery voltage to the field connector(s).
Always disconnect the battery ground cable before disconnecting the alternator lead.
NEVER subject the alternator to excessive heat or dampness. If you are steam-cleaning the engine, cover the alternator.
If arc welding is to be done on the car, disconnect the battery and alternator. Disconnect the wiring from the engine controller (PCM). This consists of 14-and 60-pin connectors on most models.