Chrysler Neon 1995 Workshop Manual

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dodge :: Dodge Neon L4-2.0L SOHC (1995)
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations
ABS Main Relay: Locations
The relay box is mounted on the Hydraulic Control Unit.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 7
ABS Main Relay: Diagrams
Relay Box
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations > Page 8
ABS Main Relay: Description and Operation ABS SYSTEM RELAY
The system relay is used for the operation of the ABS system. Power for the relay is supplied on the B57 circuit from cavity 57 of the controlmodule. Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and terminates at the left headlamp ground.
When the system is operating normally, power for the contact side of the relay is supplied from the control module on the B47 circuit. It passesthrough the relay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relayswitches from the Z1 to the F18 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams
Brake Fluid Pump Relay: Diagrams
Relay Box
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest for ABS
Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON
ABS Control Module: Customer InterestABS - Warning Lamp ON
NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994
SUBJECT:ABS Warning Lamp Illuminated
MODELS:1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX.
SYMPTOM/CONDITION:
Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brakefeature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual(Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems arefound, proceed with the following repair procedure. PARTS REQUIRED:
1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part.
1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89.
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NOTE:
THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEEILLUSTRATION.
POLICY:Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:Labor Operation No.
08-19-10-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON
ABS Control Module: All Technical Service BulletinsABS - Warning Lamp ON
NO: 05-02-94 GROUP: Brakes DATE: Feb. 4, 1994
SUBJECT:ABS Warning Lamp Illuminated
MODELS:1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT PRIOR TO 1/17/94, MDH 01-17-XX.
SYMPTOM/CONDITION:
Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation. With the lamp illuminated, the antilock brakefeature is disabled and normal power brake operation will be fully functional. The lamp will stay illuminated until the next key cycle. DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4 Antilock Brake System Diagnostic Procedure Manual(Publication No. 81-699-0420), check for Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no problems arefound, proceed with the following repair procedure. PARTS REQUIRED:
1 5269557 Controller, Antilock Brake (CAB) REPAIR PROCEDURE: This bulletin involves replacing the CAB with a revised part.
1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual (Publication No. 81-270-5025), Pg. 5-89.
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NOTE:
THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE BENDIX PART NUMBER, SEEILLUSTRATION.
POLICY:Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:Labor Operation No.
08-19-10-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 25
ABS Control Module: Locations
ABS Controller
The controller is located in the passenger compartment, on the left kick panel.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 26
Controller Connector
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 27
ABS Control Module: Description and Operation
Fig 1 Controller Anti-Lock Brake System (CAB)
Fig 2 Controller Anti-Lock System (CAB)
(CAB)
(ABS)
(HCU)
The Controller, Antilock Brake located under the lefthand side of the instrument panel is a microprocessor device which monitors wheel speedand controls Antilock Brake System . The CAB monitors the speed of each wheel through the signals generated at the wheel speed sensors todetermine if any wheel is beginning to lock. If any wheel lock is detected, the CAB commands the Hydraulic Control Unit to modulate pressureto some or all of the hydraulic circuits.
The CAB constantly monitors the ABS system for proper operation. If the CAB detects a fault, it will turn on the ABS warning lamp and disable theABS braking system. The CAB contains a self-diagnostic program which will store system faults in a diagnostic program memory. There are multiplefault messages which may be stored in the CAB memory and can be displayed with a DRB or equivalent scan tool. These faults will remain in the CABmemory even after the ignition has been turned off.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 28
ABS Control Module: Service and Repair
60-way
1. Disconnect battery ground cable.2. Disconnect wiring harness connector from CAB.3. Remove two CAB bracket to driver's side cowl mounting nuts.4. Remove CAB from vehicle.5. Reverse procedure to install, connector retaining bolt to inch lbs.torque 60-way 38
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control Module: >
070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating
Radiator Cooling Fan Control Module: Customer InterestEngine Cooling Fan - Vehicle Overheating
NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997
SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination
MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION:
Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicatorlight (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS:
Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found,proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module
1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector.
1. Record all radio pre-sets.
2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car).
3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside:
- radiator-to-battery strut
- battery thermo-guard
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer
Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 38
Neon L4-2.0L SOHC (1995)
- battery
- battery tray
- upper radiator mounts
4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws).
5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration).
6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench. Radiator Fan Motor Connector (On Vehicle):
7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute
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tubing.
8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart.
9. Strip the insulation off the end of each wire on the wire harness approximately 1".
10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowingextra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original.
11. Strip the insulation off the end of each wire on the wire harness approximately 1".
12. Slide a piece of heat shrink tubing onto each wire of the connector wiring.
13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black.
14. Solder twisted wire ends using rosin core solder.
15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink andseal the splice. Use the approved air heat gun only.
16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape.
RFI Fan Filter Module (On Bench):
17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assemblyfrom the shroud (two screws) and discard the RFI filter.
18. Stagger cut the two wires from the motor approximately 2-1/2" apart.
NOTE:
CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES.
19. Strip an inch of insulation off the end of each wire from the motor.
20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowingextra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original.
21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness.
22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring.
23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue andblack to black.
24. Solder twisted wire ends using rosin core solder.
25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink andseal the splice. Use the approved air heat gun only.
26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (onescrew).
27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.)
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > Customer
Interest for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 39
Neon L4-2.0L SOHC (1995)
28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tabsideways to lock the connector into place.
29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install theconnector to the left fan motor. Push in until the connector snaps into place.
30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install:
- upper radiator mounts
- battery tray
- battery
- battery thermo-guard
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- radiator-to battery strut
31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65lb in.). Verify proper fan operation.
32. Reset all radio pre-sets recorded in step 1.
POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating
Radiator Cooling Fan Control Module: All Technical Service BulletinsEngine Cooling Fan - Vehicle Overheating
NO: 07-01-97 GROUP: Cooling EFFECTIVE DATE: Mar. 28, 1997
SUBJECT: Vehicle Overheats And/or A/C Inoperative With No MIL Illumination
MODELS: 1995 - 1996 (PL) Neon SYMPTOM/CONDITION:
Vehicle overheats (cold/warm weather) during stop and go driving or at an extended idle, and/or A/C becomes inoperative with no malfunction indicatorlight (MIL) illuminated. Radiator fans are not operating. DIAGNOSIS:
Visually inspect the RFI connector and RFI filter module for signs of damage. If damage is found proceed to repair procedure. If no damage is found,proceed to cooling system diagnosis in the 1997 Neon Service Manual (Publication Number 81-270-7025) beginning on page 7-8. (See Illustration) PARTS REQUIRED: 1 04897717AA RFI Fan Filter Module
1 04897674AA Connector Package, Radiator Fan Motor REPAIR PROCEDURE: This bulletin involves the replacement of the RFI fan filter module and connector.
1. Record all radio pre-sets.
2. Disconnect the battery cables from the battery and body ground cable from the upper radiator closure panel (near center of car).
3. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Remove and set aside:
- radiator-to-battery strut
- battery thermo-guard
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 45
Neon L4-2.0L SOHC (1995)
- battery
- battery tray
- upper radiator mounts
4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fan module assembly (two upper screws).
5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filter assembly (Illustration).
6. Remove the entire right radiator fan module assembly (two screws). Place the fan module assy face-down on a bench.
Radiator Fan Motor Connector (On Vehicle):
7. Cut off the existing wiring connector directly behind the insulator and remove about 6 inches of tape. Slip the two fan wires from the convolute
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tubing.
8. Stagger cut the two wires on the wire harness side approximately 2-1/2" apart.
9. Strip the insulation off the end of each wire on the wire harness approximately 1".
10. Stagger cut the matching wires on the new connector wiring assembly in the opposite order as you did on the vehicle wire harness side (allowingextra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original.
11. Strip the insulation off the end of each wire on the wire harness approximately 1".
12. Slide a piece of heat shrink tubing onto each wire of the connector wiring.
13. Connect the wire harness end to the connector wire end by twisting the ends together. Be sure to match colors - green to green and black to black.
14. Solder twisted wire ends using rosin core solder.
15. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink andseal the splice. Use the approved air heat gun only.
16. Slip the wires back into the convolute tubing. Wrap the entire uncovered convolute tubing with tape.
RFI Fan Filter Module (On Bench):
17. Cut off the existing right motor wiring from the RFI filter module assy, and remove about four inches of sleeving. Remove the RFI filter assemblyfrom the shroud (two screws) and discard the RFI filter.
18. Stagger cut the two wires from the motor approximately 2-1/2" apart.
NOTE:
CUT THE WIRES AWAY FROM THE ONE-TO-TWO WIRE SPLICES.
19. Strip an inch of insulation off the end of each wire from the motor.
20. Stagger cut the matching wires on the new RFI filter module wiring harness in the opposite order as you did on the motor wiring side (allowingextra length for soldered connections.) Be sure that the overall length of the new repaired wiring is the same as the original.
21. Strip an inch of insulation off the end of each wire on the new RFI filter module wiring harness.
22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiring harness wiring.
23. Connect each RFI filter module wiring harness end to each motor wire end by twisting the ends together. Be sure to match colors - blue to blue andblack to black.
24. Solder twisted wire ends using rosin core solder.
25. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink andseal the splice. Use the approved air heat gun only.
26. Tape the wire harness over splices up to 1-1/2" behind the back of the RFI filter module box. Install the new RFI filter assembly to the shroud (onescrew).
27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.)
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Radiator Cooling Fan Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 46
Neon L4-2.0L SOHC (1995)
28. Install the new connector to the right fan motor RFI fan filter module assembly. Push in until the connector snaps into place. Slide the red tabsideways to lock the connector into place.
29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.). Route the RFI output wiring to the left fan motor, and install theconnector to the left fan motor. Push in until the connector snaps into place.
30. See instructions and warnings in the 1997 Neon Service Manual (Publication Number 81-270-7025) on Page 8A-9. Install:
- upper radiator mounts
- battery tray
- battery
- battery thermo-guard
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- radiator-to battery strut
31. Re-connect the body ground cable and battery cables. Torque body ground cable screw to 4.0 Nm (35 lb-in.) and battery terminals to 7.2 Nm (65lb in.). Verify proper fan operation.
32. Reset all radio pre-sets recorded in step 1.
POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-55-08-90 0.6 Hrs. FAILURE CODE: P8 - New Part
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations
Radiator Fan Relay: Locations
Fig.31 Power Distribution Center (PDC)
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page
50
Neon L4-2.0L SOHC (1995)
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page
51
Neon L4-2.0L SOHC (1995)
Power Distribution Center (Top)
The Power Distribution Center (PDC)
The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay,A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDCcover for location. Check electrical terminals for corrosion and repair as necessary.
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Solid State Relay
Solid State Relay
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions
Radiator Fan Relay: Diagram Information and Instructions
Circuit Function
Circuit Identification
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to theCircuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.
Circuit Information
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 54
Neon L4-2.0L SOHC (1995)
Wire Code Identification
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Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color.
Connector Information
Connector Identification
Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals. A connector identifier is placednext to the arrows to indicate the connector number.
For viewing connector pin-outs, with two or more terminals, refer to Connector Pin-Outs Index, which identifies the connector by number and providesterminal numbering, circuit identification, wire colors, and functions.
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 55
Neon L4-2.0L SOHC (1995)
All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle, refer to Connector LocationsIndex, which uses the connector identification number from the wiring diagrams to provide a figure number reference.
Electrostatic Discharge (ESD) Sensitive Devices
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Electrostatic Discharge Symbol
(ESD)
All Electrostatic Discharge sensitive components are solid state and a symbol is used to indicate this. When handling any component with thissymbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into thecomponent. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.3. When using a voltmeter, be sure to connect the ground lead first.4. Do not remove the part from its protective packing until it is time to install the part.5. Before removing the part from its package, ground the package to a known good ground on the vehicle.
Fasteners
Shock Tower To Spring Minimum Clearance Area
CAUTION:
NO
At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place ofan original plastic clip. Also, holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into thestrut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of thespring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog.
Fuses
CAUTION:
When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a ratingother than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 56
Neon L4-2.0L SOHC (1995)
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES
are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate differentconditions that may appear on the vehicle. For example, an up-to and after condition.
are used to indicate information that could prevent making an error that may damage the vehicle.CAUTIONS
WARNINGS
provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time avehicle is being serviced.
WARNING:
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- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON.
­SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. AMANUAL TRANSMISSION SHOULD BE IN NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
­TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAILPIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING.
Symbols
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 57
Neon L4-2.0L SOHC (1995)
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 58
Neon L4-2.0L SOHC (1995)
Fig.5 Symbol Identification
Various symbols are used throughout the Wiring Diagrams section. These symbols can be identified by referring to the Symbol Identification chart.
Take-Outs
The abbreviation is used in the component location section to indicate a point at which the wiring harness branches out to a component.T/O
How to Find System & Component Diagrams
Group Index
When trying to find the diagram for a specific component or system, use the information or the under Alphabetic Index to Wiring Diagrams Electrical
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Group Index Diagrams By Sheet Number
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the , , or . The reference number for the subsequent diagram will match a listed group shown.Diagrams By Figure Number
Power Distribution Center Identification
Fig.21 Power Distribution Center Identification
For Power Distribution Center fuse and relay identification, refer to figure above. For additional information on relay and fuse operation, refer to thewiring diagrams.
Wire Circuit and Gauge Identification
Fig.1 Wire Color Code Identification
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 59
Neon L4-2.0L SOHC (1995)
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Fig.2 Wire Color Codes
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. The color is shownas a two-letter code, which can be identified by referring to the Wire Color Code chart. If the wire has a tracer, and it is a standard color, an asterisk willfollow the main wire color. If the tracer is non-standard, the main wire color will have a slash (/) after it, followed by the tracer color.
Connector and Terminal Replacement
six inches
1/2 inch
1. Disconnect battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.3. Cut off the existing wire connector directly behind the insulator. Remove of tape from the harness.4. Stagger cut all wires on the harness side at intervals.5. Remove of insulation from each wire on the harness side. 1 inch
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >
Diagram Information and Instructions > Page 60
Neon L4-2.0L SOHC (1995)
length for soldered connections. Check that the overall length is the same as the original.
1 inch
7. Remove of insulation from each wire.8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
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Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2).11. Twist the wires together (Example 3).12. Solder the connection together using rosin core solder only. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of bothDo not use acid core solder.
ends of the tubing.
1-1/2 inches 2 inches
14. Repeat steps 8 through 13 for each wire.15. Re-tape the wire harness starting behind the connector and past the repair.16. Re-connect the repaired connector.17. Connect the battery and test all affected systems.
Connector Replacement
1. Disconnect the battery.2. Disconnect the connector (that is to be repaired) from its mating half/component.
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Diagram Information and Instructions > Page 61
Neon L4-2.0L SOHC (1995)
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit . Pull on the wire to remove the6680
terminal from the connector.
5. Reset the terminal locking tang, if it has one.6. Insert the removed wire in the same cavity on the repair connector.7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities.8. Insert the connector locking wedge into the repaired connector, if required.9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Diode Replacement
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Diagram Information and Instructions > Page 62
Neon L4-2.0L SOHC (1995)
Diode Identification
1. Disconnect the battery.2. Locate the diode in the harness and remove the protective covering.3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
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Do not use acid core solder.
5. Install the new diode in the harness, making sure current flow is correct.6. Solder the connection together using rosin core solder only. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements.8. Re-connect the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery.2. Disconnect the connector being repaired from its mating half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Terminal Removal
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Diagram Information and Instructions > Page 63
Neon L4-2.0L SOHC (1995)
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit . Pull on the wire to remove the6680
terminal from the connector.
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6 inches
1 inch
1 inch
5. Cut the wire from the back of the connector.6. Remove of insulation from the wire on the harness side.7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired.8. Cut the repair wire to the proper length and remove of insulation.9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
Do not use acid core solder.
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1).11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2).12. Twist the wires together (Example 3).13. Solder the connection together using rosin core solder only. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
1-1/2 inches 2 inches
15. Insert the repaired wire into the connector.16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component.17. Re-tape the wire harness starting behind the connector and past the repair.18. Connect the battery and test all affected systems.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery.2. Disconnect the connector from its mating half/component.
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Diagram Information and Instructions > Page 64
Neon L4-2.0L SOHC (1995)
Molex Connector Repair
3. Insert the terminal releasing special tool into the terminal end of the connector.6742
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Using Special Tool 6742
6742
4. Using special tool , release the locking fingers on the terminal.5. Pull on the wire to remove it from the connector.6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securelyin place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove of insulation from each end of the wire.1 inch
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Diagram Information and Instructions > Page 65
Neon L4-2.0L SOHC (1995)
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
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ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
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Radiator Fan Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause aproblem. Before condemning a component or wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problemssection.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground.2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure.
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Diagram Information and Instructions > Page 67
Neon L4-2.0L SOHC (1995)
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery.2. Connect one lead of the ohmmeter to one side of the circuit being tested.3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
6 to 8 Inches
1. Remove the fuse and disconnect all items involved with the fuse.2. Connect a test light or a voltmeter across the terminals of the fuse.3. Starting at the fuse block, wiggle the wiring harness every and watch the voltmeter/test light.4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit.2. Replace the blown fuse.3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery.4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated.
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Diagram Information and Instructions > Page 68
Neon L4-2.0L SOHC (1995)
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery.2. Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item.4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below.
- - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit.Jumper Wire
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERYFEED AND GROUND.
- Voltmeter
- This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead tothe positive side of the circuit.
CAUTION:
Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a or greater impedance.10 megohm
- Ohmmeter
- This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean goodcontinuity or a shorted circuit.
CAUTION:
10 megohm
Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter witha or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicleelectrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools 6807
- These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package and insert itinto the terminal being tested. Use the other end of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check fornon-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-onitems are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue.
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4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams.
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Radiator Fan Relay: Connector Views
Fig.21 Power Distribution Center Identification
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Neon L4-2.0L SOHC (1995)
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Power Distribution Center Front View
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Radiator Fan Relay: Electrical Diagrams
Dual Cooling Fans
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Diagram Information and Instructions > Page 72
Neon L4-2.0L SOHC (1995)
A/C & Heater System -- Sheet 8w-42-4
Chrysler Does not provide a wiring diagram for dual fans on 95-98 model year Neons. This diagram is for the 99 model year and is presentedfor reference only.
Single Cooling Fan
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Diagram Information and Instructions > Page 73
Neon L4-2.0L SOHC (1995)
Air Conditioning-Heater (Part 1 Of 2)
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Air Conditioning-Heater (Part 2 Of 2)
The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the dual fan option is mentioned.Additionally, the Radiator Fan Control is shown as a portion of the A/C circuit and as a portion of the PCM circuit.
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Description and Operation > Radiator Fan Relay Description
Radiator Fan Relay: Description and OperationRadiator Fan Relay Description
Radiator Fan Relay-PCM Output
The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars inthe Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 ampfuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC.
99C (210F) When engine coolant reaches a temperature of , the PCM energizes the radiator fan.The PCM turns the fan OFF when coolant temperature drops to .93C (199F)
Whenever the PCM energizes the A/C compressor clutch it engages the fan.Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts.
The radiator fan relay is located in the PDC.The inside top of the PDC cover has a label showing relay and fuse location. See: Diagrams/Connector Views
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Radiator Fan Relay: Description and OperationDescription of Trouble Codes
High Speed Fan Control Relay Circuit NAME OF CODE:
High Speed Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.
SET CONDITION:
An open or shorted condition is detected in the high speed radiator fan relay control circuit.
THEORY OF OPERATION:
The high speed radiator fan relay controls the high speed operation of the radiator fan. The relay is located in the power distribution center.
(PCM)
One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed whenthe other side of the relay coil is grounded by the powertrain control module . The PCM grounds the relay control circuit depending oncoolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable
POSSIBLE CAUSES:
- Relay coil open or shorted
- Fused ignition switch output circuit open
- High speed radiator fan relay control circuit open or shorted
- Inoperative circuit driver in PCM
Low Speed Fan Control Relay Circuit NAME OF CODE:
Low Speed Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.
SET CONDITION:
An open or shorted condition is detected in the low speed radiator fan relay control circuit.
THEORY OF OPERATION:
The low speed radiator fan relay controls the low speed operation of the radiator fan. The relay is located in the power distribution center.
(PCM)
One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed whenthe other side of the relay coil is grounded by the powertrain control module . The PCM grounds the relay control circuit depending oncoolant temperature. The PCM grounds the relay circuit when the engine coolant temperature is too high and removes the ground when the temperature is acceptable
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Operation > Radiator Fan Relay Description > Page 77
Neon L4-2.0L SOHC (1995)
POSSIBLE CAUSES:
- Relay coil open or shorted
- Fused ignition switch output circuit open
- High speed radiator fan relay control circuit open or shorted
- Inoperative circuit driver in PCM
Rad Fan Control Relay Circuit NAME OF CODE:
Rad Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.
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SET CONDITION:
An open or shorted condition is detected in the radiator fan relay control circuit.
THEORY OF OPERATION:
(PCM)
The radiator fan relay controls the operation of the radiator fan. The relay is located in the power distribution center. One side of the relay controlcoil is supplied with 12 volts when the ignition switch is turned to the "RUN" position. The circuit is completed when the other side of the relaycoil is grounded by the powertrain control module . The PCM grounds the relay control circuit depending on coolant temperature. Whenthe engine coolant temperature has reached the maximum temperature parameter, the relay will be grounded. Conversely, when the engine coolanttemperature has acquired the minimum temperature parameter, the relay will remove the ground.
POSSIBLE CAUSES:
- Relay coil open or shorted
- Fused ignition switch output circuit open
- Low speed radiator fan relay control circuit open or shorted
- Inoperative circuit driver in powertrain control module
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> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Radiator Fan Relay: Initial Inspection and Diagnostic Overview
-
Check the maxi fuse located in the Power Distribution center (PDC) for the radiator fan motor(s).30 Amp
-
Check the fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor clutch relays.15 Amp
-
Check the micro fuse located in the power distribution center. When checking the A/C compressor clutch relay,10 Amp
-
Check the fuse located in cavity 7 of the fuse block when checking blower motor operation,25 Amp
- Check the right headlamp ground located at the right fender side shield.
- Check the left headlamp ground located on the left side of the radiator closure panel.
- On vehicles equipped with A/C, check the refrigerant level. The system will not operate with a low level of refrigerant.
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> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Relay > Component Information > Description and Operation
Cruise Control Relay: Description and Operation NAME OF CODE:
Speed Control Power Relay Circuit
WHEN MONITORED:
With the ignition key ON, speed control switched ON, the SET button pressed and the brake pedal released.
SET CONDITION:
The speed control power supply circuit is either open or shorted to ground.
THEORY OF OPERATION:
The PCM monitors the voltage drop across all speed control solenoids and the power supply circuit.
POSSIBLE CAUSES:
- PCM misfire
- Open or shorted power supply circuit
- Failed dump solenoid (S/C servo)
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> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations
Compressor Clutch Relay: Locations
Fig.21 Power Distribution Center Identification
The relay is located in the Power Distribution Center.
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> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations
Condenser Fan Motor Relay: Locations
Fig.31 Power Distribution Center (PDC)
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Neon L4-2.0L SOHC (1995)
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Neon L4-2.0L SOHC (1995)
Power Distribution Center (Top)
The Power Distribution Center (PDC)
The power distribution center (PDC) is located next to the battery in the engine compartment. The PDC contains the starter relay, radiator fan relay,A/C compressor clutch relay, auto shutdown relay, fuel pump relay and several fuses. For the location of the relay within the PDC, refer to the PDCcover for location. Check electrical terminals for corrosion and repair as necessary.
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Solid State Relay
Solid State Relay
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> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 93
Condenser Fan Motor Relay: Description and Operation
Radiator Fan Relay-PCM Output
The PCM energizes the radiator fan through the radiator fan relay. The PCM controls the ground circuit for the solenoid side of the relay. Buss bars inthe Power Distribution Center (PDC) supply voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a 30 ampfuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the PDC.
99C (210F) When engine coolant reaches a temperature of , the PCM energizes the radiator fan.The PCM turns the fan OFF when coolant temperature drops to .93C (199F)
Whenever the PCM energizes the A/C compressor clutch it engages the fan.Also, to prevent radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts.
The radiator fan relay is located in the PDC.The inside top of the PDC cover has a label showing relay and fuse location. See: Relays and Modules - Cooling System/Radiator FanRelay/Diagrams/Connector Views
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