Volkswagen Air-Cooled 1970-1981 Repair Guide

Safety Precautions


Whenever working on or around any electrical or electronic systems, always observe these general precautions to prevent the possibility of personal injury or damage to electronic components.

Never install or remove battery cables with the key ON or the engine running. Jumper cables should be connected with the key OFF to avoid power surges that can damage electronic control units. Engines equipped with computer controlled systems should avoid both giving and getting jump starts due to the possibility of serious damage to components from arcing in the engine compartment if connections are made with the ignition ON .
Always remove the battery cables before charging the battery. Never use a high output charger on an installed battery or attempt to use any type of "hot shot" (24 volt) starting aid.
Exercise care when inserting test probes into connectors to insure good contact without damaging the connector or spreading the pins. Always probe connectors from the rear (wire) side, NOT the pin side, to avoid accidental shorting of terminals during test procedures.
Never remove or attach wiring harness connectors with the ignition switch ON , especially to an electronic control unit.
Do not drop any components during service procedures and never apply 12 volts directly to any component (like a solenoid or relay) unless instructed specifically to do so. Some component electrical windings are designed to safely handle only 4 or 5 volts and can be destroyed in seconds if 12 volts are applied directly to the connector.
Remove the electronic control unit if the vehicle is to be placed in an environment where temperatures exceed approximately 176ordm;F (80ordm;C), such as a paint spray booth or when arc/gas welding near the control unit location.