Chrysler Neon 1996 Workshop Manual

dodge :: Dodge Neon L4-2.0L DOHC (1996)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation

ABS Main Relay: Description and Operation
CIRCUIT OPERATION

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 ControllerAnti Lock Brake .(CAB)

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 CAB on the B57 circuit. It passes through therelay to the Z1 ground and terminates at the left headlamp ground. If a problem is detected in the system, the contact side of the relay switchesfrom the Z1 to the F12 circuit. This causes the ABS warning lamp in the instrument cluster to illuminate.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation

Brake Fluid Pump Relay: Description and Operation
CIRCUIT OPERATION

(CAB)

The ABS pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47 of the ControllerAnti Lock Brake on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The ground side of the coil iscontrolled by the B116 circuit. Circuit B116 connects to cavity 16 of the CAB connector.

Circuit B120 from cavity 20 of the CAB connector powers the ABS pump motor. This circuit is also used as an input to the CAB for pump motormonitoring.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation

Electronic Brake 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.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Page 13

Electronic Brake 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

> 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

> 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 23

Neon L4-2.0L DOHC (1996)

- 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

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.)

> 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 24

Neon L4-2.0L DOHC (1996)

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

- 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

> 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

> 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 30

Neon L4-2.0L DOHC (1996)

- 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

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.)

> 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 31

Neon L4-2.0L DOHC (1996)

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

- 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

> 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)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page

35

Neon L4-2.0L DOHC (1996)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page

36

Neon L4-2.0L DOHC (1996)

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.

Solid State Relay

Solid State Relay

> 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

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 39

Neon L4-2.0L DOHC (1996)

Wire Code Identification

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.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 40

Neon L4-2.0L DOHC (1996)

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

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.

Notes, Cautions and Warnings

Additional important information is presented in three ways: Notes, Cautions, and Warnings.

NOTES

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 41

Neon L4-2.0L DOHC (1996)

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:

- 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.

Positive Temperature Coefficient

Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in thejunction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids.

Positive Temperature Coefficient Symbol

A special symbol is used to identify these in the wiring diagrams.

Symbols

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 42

Neon L4-2.0L DOHC (1996)

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 43

Neon L4-2.0L DOHC (1996)

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

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

How to Read Wiring Diagrams

Wire Color Code Identification

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. 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

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 44

Neon L4-2.0L DOHC (1996)

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
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.

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

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 45

Neon L4-2.0L DOHC (1996)

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.

Connector Locking Wedge

3. Remove the connector locking wedge, if required.

Terminal Removal

Terminal Removal Using Special Tool

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 46

Neon L4-2.0L DOHC (1996)

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

Diode Identification

Do not use acid core solder.

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.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.

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Diagram Information and Instructions > Page 47

Neon L4-2.0L DOHC (1996)

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.

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

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 48

Neon L4-2.0L DOHC (1996)

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.

Molex Connector Repair

3. Insert the terminal releasing special tool into the terminal end of the connector.6742

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

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 49

Neon L4-2.0L DOHC (1996)

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

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
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.

Special Tools

Probing Tool Package 6807

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 50

Neon L4-2.0L DOHC (1996)

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams > Diagram Information and Instructions > Page 51

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.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 52

Neon L4-2.0L DOHC (1996)

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.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Diagrams >

Diagram Information and Instructions > Page 53

Neon L4-2.0L DOHC (1996)

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.

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.

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.

> 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

Radiator Fan Relay

> 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

Radiator Fan Relay: Electrical Diagrams

Dual Cooling Fans

> 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 DOHC (1996)

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.

Air Conditioning/Heater (Part 3 Of 3)

> 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

> 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 > Page 59

Radiator Fan Relay: Description and OperationDescription of Trouble Codes

High Speed Fan Relay Control Circuit
Name of Code:

High Speed Fan Control Relay Circuit

When Monitored:

With the ignition key in the run position and battery voltage above 10 volts.

Set Condition:

An open or shorted condition is detected in the high speed fan relay control circuit.

Theory of Operation:

The high speed fan relay controls the high speed operation of the radiator fans. The relay is located in the power distribution center. One side ofthe relay control coil is supplied with 12 volts when the ignition switch is turned to the run position. The circuit is completed when the other sideof the relay coil is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit when the engine coolanttemperature 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 fan relay control circuit is open or shorted

- Inoperative circuit driver in powertrain control module

Rad Fan Control Relay Circuit
Name of Code:

Rad Fan Control Relay Circuit

When Monitored:

With the ignition key on, battery voltage greater than 10 volts, and the PCM requests the fans to be turned on.

Set Condition:

An open or shorted condition is detected in the Radiator Fan Control Relay Circuit.

Theory of Operation:

Possible Causes:

- Relay Failure

- Fused B(+)

- Radiator fan relay control circuit open or shorted

- PCM Failure

- Connector terminals

The solid state radiator fan relay controls the operation of the radiator fans. One connector of the relay is supplied with fused B(+) to power thefans. This same B(+) connection powers the internal electronics in the relay. The chassis ground connection (physical attachment to the chassis) onthe relay provides a heat sink for the relay and a ground for the internal electronics. The ground connection from the relay connector is a redundantground for the internal relay electronics. If the relay attachment to the chassis becomes loose or corroded the relay could fail due to its inability todissipate heat through the chassis attachment. when the relay control circuit is grounded by the PCM, current flows through the relay to the fans.As the engine temperature rises to a preset level, the PCM will start sending a "Pulse Width Modulated" (PWM) ground signal to the relay. Thedwell time of the signal will increase or decrease from 30% to 100% based on the engine coolant temperature and A/C pressures. this method ofcontrolling the fans provides an infinitely variable fan speed.

- Connector Wires

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

Compressor Clutch Relay: Locations

Power Distribution (Part 1 Of 2)

Fig. 15 Power Distribution Center (PDC)

> 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)

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 67

Neon L4-2.0L DOHC (1996)

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 68

Neon L4-2.0L DOHC (1996)

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.

Solid State Relay

Solid State Relay

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 69

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

> Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Description and Operation

Battery Discharge Protection Relay: Description and Operation

Halo Lamp/Time Delay Relay

CIRCUIT OPERATION

The time delay relay is used to allow a time-ON function for the ignition switch halo lamp. Power for the relay is received on the M1 circuit fromthe fuse located in the Power Distribution Center (PDC). This is the Ignition-Off Draw (IOD) fuse and HOT at all times.10 Amp

When a door is OPENED, or the headlamp switch is moved to the dome lamp position, a ground path is provided for the relay on the M2 circuit.This energizes the relay, CLOSING the contacts. When the relay contacts are CLOSED, power is provided through the relay to the M50 circuit.

The M50 circuit supplies current to the ignition switch lamp in the steering column. Ground for the lamp is provided on the Z3 circuit. This circuitsplices with the glove box lamp, the ash receiver lamp, and the PRNDL lamp. The Z3 circuit terminates at the instrument panel left center support.

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Description and Operation

Daytime Running Lamp Control Unit: Description and Operation
CIRCUIT OPERATION

On vehicles built for sale in Canada, the headlamps operate, at reduced intensity, when the ignition switch is in the RUN position and the parkingbrake switch is OPEN.

(PDC)

In the Power Distribution Center , a bus bar connected to battery voltage feeds circuit A1. In the RUN position, the ignition switch connectscircuit A1 to circuit A21. A fuse in the PDC, protects circuits A1 and A21.30 Amp

5 Amp

Circuit A21 connects to a bus bar in the fuse block. The bus bar in the fuse block feeds circuit G5 through a fuse in cavity 11. Circuit G5 ispowered only when the ignition switch is in the RUN position.

Circuit G9 connects to the DRL module. The G9 circuit splices to the brake warning switch, park brake switch and instrument cluster brakewarning bulb.

Circuit L20 from the headlamp and dimmer switch supplies battery voltage to the DRL module at all times. Circuit A3 from the PDC feeds circuitL20. A fuse in the PDC protects the A3 circuit.40 Amp

From the DRL module, circuit L4 powers the LOW beams of the left and right headlamps. The DRL controls the power to circuit L4. Circuit L4connects to cavity 10 of the Daytime Running Lamp module.(DRL)

Circuit L3 feeds the high beams of the headlamps. When the operator flashes the headlamps with the stalk of the multi-function switch, the DRLsenses voltage on circuit L3. When it senses voltage on circuit L3, the DRL module stops supplying power to the low beams on circuit L4.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

Horn Relay: Locations

Power Distribution (Part 1 Of 2)

Fig. 15 Power Distribution Center (PDC)

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 80

Horn Relay: Testing and Inspection

The content of this article reflects changes called for in TSB 26-03-96.
Horn Relay

1. Remove horn relay.2. Using ohmmeter, test for continuity between ground and circuit 65 of horn relay.

a. When the horn switch is not depressed, no continuity should be present.b. Continuity to ground when the horn switch is pdepressed.c. If continuity is not correct, repair the horn switch or wiring as necessary.

3. Insert a jumper wire between circuit 63 and 66 of the Power Distribution Center.
a. If horn sounds, replace relay.b. If horn does not sound, install horn relay and refer to Horn Test.

4. Using voltmeter, test voltage at:
a. Circuit 62 and 66 test for battery voltage from fuse C to body ground.b. If voltage is incorrect, repair as necessary. Refer to wiring diagrams.

5. Check relay for 70-75 ohms resistance from terminal 85 to 86. If resistance not OK, replace relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 81

Horn Relay: Service and Repair

The content of this article reflects changes called for in TSB 26-03-96.
Horn Relay

1. Remove power Distribution Center cover and locate the horn relay.

2. Remove the horn relay.

Installation

For installation, reverse above procedures.

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Locations

Fuse/Fuse Block (Part 1 Of 2)

> Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation

Interior Lighting Relay: Description and Operation
CIRCUIT OPERATION

The time out relay is located in the fuse block and is used to control the ground path for various interior lamps. It will also turn the lamps OFFafter a specified period of time, and works with the Remote Keyless Entry system for illuminated entry.(RKE)

Circuit M2 connects to the relay and supplied a ground path through the door ajar switches.

10 Amp

Circuit M1 is used to supply battery voltage to the relay. This circuit is produced by a fuse located in cavity 13 of the Power DistributionCenter (PDC).
Circuit M32 is connected from the relay to the various interior lamps and RKE module.

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations

Relay Box: Locations

Fig.31 Power Distribution Center (PDC)

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 92

Neon L4-2.0L DOHC (1996)

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.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII Readiness Code Retention

Powertrain Control Module: Customer InterestPCM - OBDII Readiness Code Retention

NUMBER: 18-005-01
GROUP: Vehicle Performance
DATE: Feb. 16, 2001

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-18-97,DATED MAY 9, 1997, WHICH SHOULD BE REMOVED FROM YOURFILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVEBEEN USED TO HIGHLIGHT REVISIONS.

SUBJECT:OBDII Readiness Code Retention

OVERVIEW:This bulletin involves reprogramming the Powertrain Control Module.

MODELS:1995-1996

(JA) Cirrus/Stratus/Breeze
1996 (JX) Sebring Convertible
1996 (LH) Intrepid/Vision/Concorde/LHS
1996 (PL) Neon

NOTE:

THIS INFORMATION APPLIES TO FEDERAL EMISSION (SALES CODE NAA) AND CALIFORNIA EMISSION (SALES CODE NAE)MODELS BUILT PRIOR TO NOV. 21, 1995 (MDH1121XX) AND ALL 1995 JA MODELS EQUIPPED WITH A 2.0L ENGINE ANDMANUAL TRANSAXLE. THE CALIFORNIA EMISSION MODELS ADDRESSED IN THIS BULLETIN WERE SOLD IN THE NORTHEASTSTATES. CALIFORNIA MODELS SOLD IN CALIFORNIA WERE ADDRESSED WITH RECALL 678 DATED SEPT. 1996.

DISCUSSION:The On Board Diagnostic (OBDII) system includes a monitor called readiness codes. The readiness codes indicate that all OBDII diagnostic tests havebeen performed and that diagnostic trouble codes (DTC's) can be read. It has been determined that the readiness codes may be cleared upon ignition key"OFF" cycles. Absence of readiness codes may cause owners to fail their emission inspection. To correct this condition, the Powertrain Control Module(PCM) must be reprogrammed.

PARTS REQUIRED:

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine

Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 18-005-01 > Feb > 01 > PCM - OBDII

Readiness Code Retention > Page 103

Neon L4-2.0L DOHC (1996)

EQUIPMENT REQUIRED:

NOTE:

THE MDS2 MUST BE OPERATING WITH CIS CD2075 OR HIGHER

1. Flash the PCM using the MDS2 (Mopar Diagnostic System) and DRBIII(R) (Scan Tool).

NOTE:

THE FOLLOWING STEPS ARE REQUIRED BY LAW.

2.

POLICY:Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

FAILURE CODE: