Chrysler Neon 1997 Workshop Manual

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dodge :: Dodge Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement
Keyless Entry Module: Service and RepairReplacement REMOVAL
1. Remove the right trim panel.2. Disconnect wire connector from RKE module.
RKE Module Location
INSTALLATION
- For installation, reverse above procedures.
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> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 8
Keyless Entry Module: Service and RepairProgram Remote Keyless Entry Module
1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector.
2. Using a jumper wire, ground the RKE programming line.3. Turn ignition switch to the ON position.4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming.
5. Disconnect the programming line from ground. This returns the system to its normal operation mode.6. Replace all removed components. Return programming line to its original position. Check for system operation.
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> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement
Keyless Entry Module: Service and RepairReplacement REMOVAL
1. Remove the right trim panel.2. Disconnect wire connector from RKE module.
RKE Module Location
INSTALLATION
- For installation, reverse above procedures.
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> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Replacement > Page 14
Keyless Entry Module: Service and RepairProgram Remote Keyless Entry Module
1. Retrieve the programming line from the upper edge of the passenger side cowl trim panel. The RKE Programming Line is a green wire with a red bullet connector.
2. Using a jumper wire, ground the RKE programming line.3. Turn ignition switch to the ON position.4. Press any button on the transmitter to set code. The locks will cycle to confirm programming. If there is a second transmitter it must be set at this time. Press any button on the second transmitter and wait for the locks to cycle to confirm programming.
5. Disconnect the programming line from ground. This returns the system to its normal operation mode.6. Replace all removed components. Return programming line to its original position. Check for system operation.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations
System Relay And Pump Motor Relay Box
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay
ABS Main Relay: Description and OperationABS System Relay CIRCUIT OPERATION
(ABS)
The system relay is used for the operation of the Anti Lock Brake system. Power for the relay is supplied on the B57 circuit from cavity 57of the Controller Anti 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.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation > ABS System Relay > Page 21
ABS Main Relay: Description and OperationABS System Relays
System Relay And Pump Motor Relay Box
SYSTEM RELAY
(ABS)
The main purpose of the system relay is to put the Antilock Brake System into a stand-by mode for ABS operation. The System Relay isenergized by the Controller Antilock Brake () shortly after the ignition switch is turned on.CAB
When Energized
- by the CAB, the System Relay turns off the ABS warning lamp and provides 12 volts to the CAB. This voltage can then beused by the CAB to energize the Decay Solenoids during ABS braking. When energized, the System Relay also provides the Pump/Motor Relaycoil with 12 volts. The ground path to the Pump/Motor Relay is completed by the CAB during ABS braking.
When De-energized
- the ABS warning lamp is illuminated, voltage to the Decay Solenoids is cut off, and the Pump/Motor Relay is preventedfrom energizing. Typically, the System Relay is de-energized by the CAB when a fault is detected that requires turning ABS off.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description
Brake Fluid Pump Relay: Description and OperationDescription
System Relay And Pump Motor Relay Box
PURPOSE
Pump/Motor power is supplied by the Pump/Motor Relay. The pump motor relay is also part of the relay box mounted to the Hydraulic ControlUnit (). If pump/motor relay replacement is required, it is also only serviced by the replacement of the relay box assembly.HCU
FUNCTION
CAB (ABS)
Voltage for the 12 volt side of the relay coil is provided by the System Relay. The ground path through the relay coil is completed by the Controller Antilock Brake () during Antilock Brake System braking. The relay contacts are closed when the relay is energized. Thisprovides 12 volts to the pump/motor as needed during ABS braking.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Description and Operation > Description > Page 26
Brake Fluid Pump Relay: Description and OperationCircuit Operation CIRCUIT OPERATION
(ABS)
(CAB)
The Anti Lock Brake pump motor relay controls when the pump motor runs. Power for the coil side of the relay is supplied from cavity 47of the Controller Anti Lock Brake on the B47 circuit. This circuit also supplies voltage for the contact side of the system relay The groundside of the coil is controlled 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.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations
Electronic Brake Control Module: Locations
CAB 60-Way Wiring Harness Connector
Controller Antilock Brake
The CAB is mounted under the instrument panel behind the drivers side kick panel of the vehicle.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 30
Electronic Brake Control Module: Description and Operation
Controller Antilock Brake
PURPOSE
(CAB) (ABS)
The Controller Antilock Brake is a microprocessor based device which monitors the Antilock Brake System during normal brakingand controls it when in an ABS stop. The CAB is mounted under the instrument panel on the drivers side kick panel. The CAB uses a 60 wayelectrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the Run or On position.
The CAB is not on the Chrysler Collision Detection bus.NOTE: (CCD)
THE PRIMARY FUNCTIONS OF THE CAB
- Detect wheel locking tendencies.
- Control fluid modulation to the brakes while in ABS mode.
- Monitor the system for proper operation.
- Provide communication to the DRB scan tool while in diagnostic mode.
The CAB Continuously Monitors
(HCU)
- the speed of each wheel through the signals generated at the Wheel Speed Sensors to determine if any wheelis beginning to lock. When a wheel locking tendency is detected, the CAB commands the Hydraulic Control Unit to modulate brake fluidpressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency isno longer present.
The ABS System Is Constantly Monitored
- by the CAB for proper operation. If the CAB detects a fault, it will turn on the Amber ABSWarning Lamp and disable the ABS braking system. The normal Non ABS braking system will remain operational.
- which will turn on the Amber ABS Warning Lamp when a ABS system fault is detected.The CAB Contains A Self-diagnostic Program
Faults Are Then Stored
- in a diagnostic program memory. There are multiple fault messages which may be stored in the CAB and displayedthrough the DRB. These fault messages will remain in the CAB memory even after the ignition has been turned off. The fault messages can becleared by using the DRB diagnostics tester, or they will be automatically cleared from the memory after the vehicle is driven approximately3500 miles.
CONTROLLER ANTILOCK BRAKE INPUTS
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^ Four wheel speed sensors.^ Stop lamp switch.^ Ignition switch.^ System relay voltage.^ Ground.^ Pump/Motor Relay Monitor^ Diagnostics Communications
CONTROLLER ANTILOCK BRAKE OUTPUTS
^ 4 Decay Solenoids^ ABS warning lamp.^ System relay actuation.^ Diagnostic communication.^ Pump motor relay actuation
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 31
Electronic Brake Control Module: Service and Repair
Controller Antilock Brake
REMOVE
1. Turn vehicle ignition off.
CAB 60-Way Wiring Harness Connector
2. Disconnect the wiring harness 60 way connector from the Controller Antilock Brake Module . Verify that the vehicle ignition is off before(CAB)
removing the 60 way connector.
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> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 32
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
CAB Bracket To Kick Panel Mounting
3. Remove the 2 controller bracket to drivers side cowl mounting nuts.4. Remove the CAB from the vehicle.
INSTALL
1. Install CAB and mounting bracket on mounting studs located on passenger side kick panel.
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2. Install the 2 CAB bracket mounting nuts and securely tighten.3. Install the 60-way wiring harness connector by hand into the 60-way CAB connector, as far as possible. Then use the CAB connector retaining bolt to fully seat wiring harness connector into the CAB.
4. Torque the 60-way connector retaining bolt to 5. If a new CAB is being has been installed, it must be initialized prior to the vehicle being driven. The CAB is initialized using the DRB Scan Tool4 Nm (38 inch lbs.).
and the initializing procedure described upon selecting Bendix ABX-4 Diagnostics. New controllers are programmed to flash the ABS warninglamp until initialized by the installing technician.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7692 > May > 98 > Recall-
Radiator Fan Relay
Technical Service Bulletin # 7692
Recall- Radiator Fan Relay
No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers
Subject:Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay
Models:1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) ThroughSeptember 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692
The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. Inaddition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violatesU.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiatorfan relay must be replaced and a jumper wire that contains a diode must be installed.
:IMPORTANT
This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must havethe recall service completed before registration renewal.
The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner uponcompletion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the currentdealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN)sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved.Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan RelayPackages, PN CKF07690, to service about 25% of those vehicles.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 42
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Each parts package contains the following components: Quantity Description
1 Radiator Fan Relay 1 Wiring Jumper Assembly 2 Tie Straps
California Recall Completion Label Requirement
There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealersare requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service
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Procedure of this letter for application instructions. Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner ordealer reference as needed. Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notificationservice completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim.
:Note
See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available
If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the OwnerNotification Form or describe the reason on a postcard and mail to:
Chrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action please contact your Zone Service Office.
A. Install the Jumper Harness
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 43
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
2. Raise the vehicle on an appropriate hoist.
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3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1).
4. Disconnect the fan motor wiring harness connector from the fan support (if necessary).
5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support.
6.
Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that theconnector faces toward the outboard (left) side of the vehicle (Figure 2).
7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2).
8.
Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the lockedposition.
9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position.
10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 44
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
NOTE:
Make sure that the wiring does not interfere with any other components.
B. Replace the Radiator Fan Relay
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1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3).
2. Disconnect the radiator fan relay wiring connector.
3. Remove and discard the radiator fan relay.
4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws.
5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
6. Lower the vehicle.
7. Connect the negative battery cable.
C. Install the Authorized Label
1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086).
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment.
D. Complete Proof of Correction Form
1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner.
Dealer Service Instructions IMPORTANT
DEALER SERVICE INSTRUCTIONS
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 45
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^
This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and:
^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692 ^
The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must bereplaced and a jumper wire that contains a diode must be installed. ^
Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number forTSB 07-07-97 and 07-04-98 is being canceled.
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^
For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (FormNo. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^
Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of thosevehicles.
Owner Letter
EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is...
The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat.In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored componentviolates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do...
Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumperharness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments arescheduled and processed. What you must do... ^
Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before yourappointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done...
The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that everyvehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may bemore likely to fail this test and require that you make costly repairs.
Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon aspossible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed...
State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recallservice performed. If your vehicle is not on this list the state will know that the recall has been completed.
Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this formsince the California Department of Motor Vehicles may require that you supply it as proof of recall completion.
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If you need help...
If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist youin getting your vehicle repaired.
We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks foryour attention to this important matter.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Recalls: > 7691 > May > 98 > Recall -
Radiator Fan Relay
Technical Service Bulletin # 7691
Recall - Radiator Fan Relay
No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers
Subject:Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay
Models:1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) ThroughSeptember 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692
The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. Inaddition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violatesU.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiatorfan relay must be replaced and a jumper wire that contains a diode must be installed.
:IMPORTANT
This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must havethe recall service completed before registration renewal.
The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner uponcompletion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the currentdealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN)sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved.Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan RelayPackages, PN CKF07690, to service about 25% of those vehicles.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 50
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Each parts package contains the following components: Quantity Description
1 Radiator Fan Relay
1 Wiring Jumper Assembly
2 Tie Straps California Recall Completion Label Requirement
There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealersare requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service
Page 40
Procedure of this letter for application instructions. Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner ordealer reference as needed. Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notificationservice completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim.
:Note
See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available
If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the OwnerNotification Form or describe the reason on a postcard and mail to:
Chrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action please contact your Zone Service Office.
A. Install the Jumper Harness
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.
Page 41
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 51
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
2. Raise the vehicle on an appropriate hoist.
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3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1).
4. Disconnect the fan motor wiring harness connector from the fan support (if necessary).
5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support.
6.
Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that theconnector faces toward the outboard (left) side of the vehicle (Figure 2).
7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2).
8.
Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the lockedposition.
9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position.
10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 52
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
NOTE:
Make sure that the wiring does not interfere with any other components.
B. Replace the Radiator Fan Relay
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1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3).
2. Disconnect the radiator fan relay wiring connector.
3. Remove and discard the radiator fan relay.
4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws.
5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
6. Lower the vehicle.
7. Connect the negative battery cable.
C. Install the Authorized Label
1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086).
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment.
D. Complete Proof of Correction Form
1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner.
Dealer Service Instructions IMPORTANT
DEALER SERVICE INSTRUCTIONS
Page 45
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Recalls: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 53
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^
This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and:
^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692 ^
The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must bereplaced and a jumper wire that contains a diode must be installed. ^
Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number forTSB 07-07-97 and 07-04-98 is being canceled.
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^
For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (FormNo. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^
Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of thosevehicles.
Owner Letter
EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is...
The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat.In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored componentviolates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do...
Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumperharness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments arescheduled and processed. What you must do...
^
Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before yourappointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer.
If you need help... ^
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assistyou in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may alsocontact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C.20460.
In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate infuture recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack ofproper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test.
We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks foryour attention to this important matter.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > Customer Interest: > 07-04-98 > Apr >
98 > Cooling System - Fan ON Continuously/Overheats
Technical Service Bulletin # 07-04-98
Cooling System - Fan ON Continuously/Overheats
NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998
SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED INTHE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PARTNUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS.
MODELS: 1997 - 1998 (PL) Neon
: NOTE
THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCAASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan
**1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap
POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay.
1. Raise the hood and disconnect the negative battery cable.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 59
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Page 50
2. Raise the vehicle on a suitable hoist.
3.
Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, anddisconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so thefan is not damaged.
4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement.
5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness:
A.
Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of thevehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2).
B.
Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into thelocked position.
6.
Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. Ifthe original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > Customer Interest: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 60
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places.
:NOTE
ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS.
8.
The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid statefan relay.
9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay.
10.
Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the twoscrews and torque to 5 N.m (45 in.lbs.).
Page 52
11. Connect the four way connector and slide the red latch into the locked position.
12. Lower the vehicle and connect the negative battery cable.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions
Solid State Fan Relay: All Technical Service BulletinsCooling System - Cooling Fan Relay Pin-Out Revisions
NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models:1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 66
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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10
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 67
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 68
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 69
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
110
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111
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay
Technical Service Bulletin # 7692
Recall- Radiator Fan Relay
No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers
Subject:Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay
Models:1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) ThroughSeptember 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692
The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. Inaddition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violatesU.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiatorfan relay must be replaced and a jumper wire that contains a diode must be installed.
:IMPORTANT
This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must havethe recall service completed before registration renewal.
The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner uponcompletion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the currentdealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN)sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved.Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan RelayPackages, PN CKF07690, to service about 25% of those vehicles.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 74
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Each parts package contains the following components: Quantity Description
1 Radiator Fan Relay
1 Wiring Jumper Assembly
2 Tie Straps California Recall Completion Label Requirement
There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealersare requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service
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Procedure of this letter for application instructions. Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner ordealer reference as needed. Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notificationservice completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim.
:Note
See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available
If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the OwnerNotification Form or describe the reason on a postcard and mail to:
Chrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action please contact your Zone Service Office.
A. Install the Jumper Harness
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 75
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
2. Raise the vehicle on an appropriate hoist.
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3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1).
4. Disconnect the fan motor wiring harness connector from the fan support (if necessary).
5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support.
6.
Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that theconnector faces toward the outboard (left) side of the vehicle (Figure 2).
7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2).
8.
Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the lockedposition.
9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position.
10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps.
Page 69
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 76
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
NOTE:
Make sure that the wiring does not interfere with any other components.
B. Replace the Radiator Fan Relay
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1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3).
2. Disconnect the radiator fan relay wiring connector.
3. Remove and discard the radiator fan relay.
4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws.
5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
6. Lower the vehicle.
7. Connect the negative battery cable.
C. Install the Authorized Label
1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086).
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment.
D. Complete Proof of Correction Form
1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner.
Dealer Service Instructions IMPORTANT
DEALER SERVICE INSTRUCTIONS
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7692 > May > 98 > Recall- Radiator Fan Relay > Page 77
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^
This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and:
^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692 ^
The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must bereplaced and a jumper wire that contains a diode must be installed. ^
Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number forTSB 07-07-97 and 07-04-98 is being canceled.
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^
For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (FormNo. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^
Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of thosevehicles.
Owner Letter
EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is...
The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat.In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored componentviolates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do...
Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumperharness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments arescheduled and processed. What you must do... ^
Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before yourappointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you don't get this done...
The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that everyvehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may bemore likely to fail this test and require that you make costly repairs.
Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon aspossible. Failure to do so could be determined as lack of proper maintenance of your vehicle. How the state knows that the recall has been performed...
State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recallservice performed. If your vehicle is not on this list the state will know that the recall has been completed.
Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this formsince the California Department of Motor Vehicles may require that you supply it as proof of recall completion.
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If you need help...
If you have trouble getting your vehicle repaired please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist youin getting your vehicle repaired.
We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks foryour attention to this important matter.
Page 74
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay
Technical Service Bulletin # 7691
Recall - Radiator Fan Relay
No. 7691 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers
Subject:Emissions Recalls # 7691 and # 7692 -- Radiator Fan Relay
Models:1997 and 1998 Model Year Dodge and Plymouth Neon (PL) Vehicles Built at the Toluca Assembly Plant ("T" in the 11th VIN Position) ThroughSeptember 10, 1997 (MDH 0910XX) and: ^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692
The radiator fan relay on about 45,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. Inaddition, radiator fan relay operation is monitored by the vehicles On Board Diagnostic (OBD) system. Failure of an OBD monitored component violatesU.S. Environmental Protection Agency (EPA) and California Air Resources Board (GARB) emission regulations. To correct this condition, the radiatorfan relay must be replaced and a jumper wire that contains a diode must be installed.
:IMPORTANT
This recall (# 7692) is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must havethe recall service completed before registration renewal.
The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner uponcompletion of the Recall # 7692 service, for use as proof in renewal of the vehicle registration. Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the currentdealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN)sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed ifknown. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTERFUNCTION" prompt, then type "ORD7691" (vehicles out of California) or ORD7692" (vehicles in California). Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved.Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Fan RelayPackages, PN CKF07690, to service about 25% of those vehicles.
Page 75
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 82
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Each parts package contains the following components: Quantity Description
1 Radiator Fan Relay
1 Wiring Jumper Assembly
2 Tie Straps California Recall Completion Label Requirement
There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall (# 7692) was completed. Dealersare requested to order the required Authorized Modifications label, PN 04275086, as necessary to support scheduled repairs. Refer to the Service
Page 76
Procedure of this letter for application instructions. Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to scheduleappointments for this service with their dealers. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner ordealer reference as needed. Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notificationservice completions and provide dealer payments. Use the following labor operation number and time allowance: Install jumper wire and replace fan relay Labor Operation Number Time Allowance 07769182 0.3 hours Add the cost of the parts package plus applicable dealer allowance to your claim.
:Note
See the Warranty Administration Manual Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available
If a vehicle is not available for service for a known reason let us know by filling out the pre-addressed Vehicle Disposition Form portion of the OwnerNotification Form or describe the reason on a postcard and mail to:
Chrysler CorporationCIMS 482-00-85800 Chrysler Drive EastAuburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action please contact your Zone Service Office.
A. Install the Jumper Harness
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock,radio settings, etc.) when you have completed the service procedure.
Page 77
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 83
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
2. Raise the vehicle on an appropriate hoist.
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3. Disconnect the left (driver side) black fan motor electrical connector by retracting the red latch and depressing the thumb latch (Figure 1).
4. Disconnect the fan motor wiring harness connector from the fan support (if necessary).
5. Disconnect the two (2) push-in fasteners that secure the radiator fan section of the main electrical harness to the lower radiator support.
6.
Attach the push-in clip on the male connector of the provided jumper harness into the outboard hole in the lower radiator support so that theconnector faces toward the outboard (left) side of the vehicle (Figure 2).
7. Attach the other jumper harness clip into the inboard hole in the lower radiator support (Figure 2).
8.
Connect the main wiring harness radiator fan electrical connector to its mating connector on the jumper harness. Slide the red latch to the lockedposition.
9. Connect the other end of the jumper harness to the fan motor harness. Slide the red latch to the locked position.
10. Bundle the excess fan wiring and secure it to the main wiring harness with the two (2) provided tie straps.
Page 79
> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 84
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
NOTE:
Make sure that the wiring does not interfere with any other components.
B. Replace the Radiator Fan Relay
Page 80
1. Locate the radiator fan relay on the left front inner frame rail just behind the radiator (Figure 3).
2. Disconnect the radiator fan relay wiring connector.
3. Remove and discard the radiator fan relay.
4. Install the new radiator fan relay. Tighten the fasteners to 45 in-lbs (5 N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the screws.
5. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
6. Lower the vehicle.
7. Connect the negative battery cable.
C. Install the Authorized Label
1. Type or print (with a ball point pen) the following information (Figure 4) on the Authorized Modifications label (PN 4275086).
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label located in the engine compartment.
D. Complete Proof of Correction Form
1. Complete a Vehicle emission Recall Proof of Correction Form and supply it to the vehicle owner.
Dealer Service Instructions IMPORTANT
DEALER SERVICE INSTRUCTIONS
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 7691 > May > 98 > Recall - Radiator Fan Relay > Page 85
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
Emissions Recalls # 7691 and # 7692-- Radiator Fan Relay ^
This service requirement applies only to 1997 and 1998 model year Dodge and Plymouth Neon (PL) vehicles built at the Toluca Assembly Plant("T" in the 11th VIN Position) through September 10, 1997 (MDH 0910XX) and:
^ Currently Located Out of California -- Recall # 7691
^ Currently Located In California -- Recall # 7692 ^
The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. To correct this condition, the radiator fan relay must bereplaced and a jumper wire that contains a diode must be installed. ^
Effective immediately all repairs on involved vehicles are to be performed according to this recall notification. The Labor Operation Number forTSB 07-07-97 and 07-04-98 is being canceled.
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^
For vehicles currently located in California involved in Recall # 7692: Be sure to provide a Vehicle Emission Recall Proof of Correction Form (FormNo. 81-016-1053) to each owner upon completion of the recall service, for owner use as proof during renewal of the vehicle registration. Parts Packages: ^
Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Fan Relay Packages to service about 25% of thosevehicles.
Owner Letter
EMISSIONS RECALL TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND INSTALL A WIRING JUMPER HARNESS Dear Dodge or Plymouth Neon Owner: Chrysler has determined that some 1997 and 1998 Dodge and Plymouth Neon vehicles may be in violation of Federal Emissions Regulations. The problem is...
The radiator fan relay on your Neon (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to overheat.In addition, radiator fan relay operation is monitored by the vehicles On-Board Diagnostic system (OBD). Failure of an OBD monitored componentviolates U.S. Environmental Protection Agency (EPA) Emission Regulations. What Chrysler and your dealer will do...
Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and install a wiring jumperharness. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on how dealer appointments arescheduled and processed. What you must do...
^
Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before yourappointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer.
If you need help... ^
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assistyou in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may alsocontact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, D.C.20460.
In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate infuture recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack ofproper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test.
We're sorry for any inconvenience, but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thanks foryour attention to this important matter.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats
Technical Service Bulletin # 07-04-98
Cooling System - Fan ON Continuously/Overheats
NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998
SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED INTHE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PARTNUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS.
MODELS: 1997 - 1998 (PL) Neon
: NOTE
THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCAASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan
**1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap
POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay.
1. Raise the hood and disconnect the negative battery cable.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 90
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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2. Raise the vehicle on a suitable hoist.
3.
Locate the left (driver's side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, anddisconnect the connector from the fan (Figure 1). If the wiring to the fan motor is clipped into the fan support, gently pry it out of the hole so thefan is not damaged.
4. Pry out the two christmas tree type retainers located on the lower radiator enclosure reinforcement.
5. Install the jumper wire assembly (p/n 052931 57AA) between the radiator fan and the headlamp and dash harness:
A.
Attach the black two-way male connector with the clip into the outboard hole, so the connector faces outboard toward the left side of thevehicle. Attach the second clip into the inboard hole of the lower reinforcement that the original wiring came out of (Figure 2).
B.
Connect the original two-way black connector to the new mating connector installed in the previous step and slide the red latch into thelocked position.
6.
Connect the two-way female black connector on the new jumper assembly to the fan connector and slide the red latch into the locked position. Ifthe original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the same hole.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Solid State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats > Page 91
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
7. Bundle the excess original fan wiring and tie strap to the main bundle of vehicle wiring in the front left corner in two places.
:NOTE
ENSURE THAT THE WIRING BUNDLE IS SECURE AND DOES NOT INTERFERE WITH ANY OTHER COMPONENTS.
8.
The solid state fan relay is located on the left front rail. Retract the red latch on the black four-way connector and disconnect from the solid statefan relay.
9. Remove the two screws that secure the relay to the side of the left front rail and remove the relay.
10.
Install the new solid state fan relay ** (p/n 04707286)** and locate the index pin on the relay into the locator hole in the rail. Secure with the twoscrews and torque to 5 N.m (45 in.lbs.).
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11. Connect the four way connector and slide the red latch into the locked position.
12. Lower the vehicle and connect the negative battery cable.
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid
State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions
Solid State Fan Relay: All Technical Service BulletinsCooling System - Cooling Fan Relay Pin-Out Revisions
NUMBER: 26-06-98D GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models:1997 2.0L, 2.4L, 2.5L, 3.3L, 3.5L SFI Diagnostic Manual - Publication Number 81-699-96040 DESCRIPTION OF CHANGES Revision to the PL body radiator fan relay connector pin out
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 97
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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10
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 98
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 99
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Solid State Fan Relay: > 26-06-98D > Jun > 98 > Cooling System - Cooling Fan Relay Pin-Out Revisions > Page 100
Neon L4-122 2.0L DOHC VIN Y SFI (1997)
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> Relays and Modules > Relays and Modules - Cooling System > Solid State Fan Relay <--> [Radiator Cooling Fan Motor Relay] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Solid
State Fan Relay: > 07-04-98 > Apr > 98 > Cooling System - Fan ON Continuously/Overheats
Technical Service Bulletin # 07-04-98
Cooling System - Fan ON Continuously/Overheats
NO: 07-04-98 GROUP: Cooling DATE: Apr. 17, 1998
SUBJECT: Vehicle Overheats (Radiator Fan Inoperative) Or Radiator Fan Runs Continuously
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 07-07-97 DATED FEBRUARY 20, 1998 WHICH SHOULD BE NOTED INTHE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-98004). THE REVISION PROVIDES A NEW PARTNUMBER FOR THE RADIATOR FAN RELAY. THE CHANGE IS HIGHLIGHTED WITH ASTERISKS.
MODELS: 1997 - 1998 (PL) Neon
: NOTE
THIS BULLETIN APPLIES TO VEHICLES BUILT AT TOLUCA ASSEMBLY PRIOR TO SEPTEMBER 11, 1997 (MDH 0911XX). TOLUCAASSEMBLY IS DESIGNATED BY A "T" IN THE ELEVENTH POSITION OF THE VEHICLE IDENTIFICATION NUMBER. SYMPTOM/CONDITION: Vehicle overheats or radiator fan continues to run. DIAGNOSIS: Actuate the radiator fan relay using the DRB III. If the radiator fan does not come on or fan runs continuously, perform the Repair Procedure. PARTS REQUIRED: 1 05293157AA Jumper Wire With Diode, Radiator Fan
**1 04707286 Relay, Radiator Fan** 2 06015756 Tie Strap
POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-65-12-92 0.3 Hrs. FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing a radiator fan jumper wire assembly into the headlamp and dash wiring harness, and replacing the solid state relay.
1. Raise the hood and disconnect the negative battery cable.
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