Dodge Neon 2.0 SOHC (1995) Workshop Manual

Factory Workshop Manual

Dodge

Neon

L4-2.0L SOHC (1995)

Anonymous

1st January 2018

Make

Model

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This manual was submitted by

Date

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Locations

ABS Main Relay: Locations
The relay box is mounted on the Hydraulic Control Unit.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Locations > Page 7

ABS Main Relay: Diagrams
Relay Box
Relay Box Connector

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Locations > Page 8

ABS Main Relay: Description and Operation
ABS SYSTEM RELAY
The system relay is used for the operation of the ABS system. Power for the relay is supplied on

the B57 circuit from cavity 57 of the control module.
Ground for the relay is on the Z1 circuit. This ground is spliced in with the pump motor, and

terminates at the left headlamp ground.
When the system is operating normally, power for the contact side of the relay is supplied from the

control module on the B47 circuit. It passes through the relay to the Z1 ground and terminates at
the left headlamp ground. If a problem is detected in the system, the contact side of the relay
switches from the Z1 to the F18 circuit. This causes the ABS warning lamp in the instrument cluster
to illuminate.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump
Relay > Component Information > Diagrams

Brake Fluid Pump Relay: Diagrams
Relay Box
Relay Box Connector

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Customer Interest
for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON

ABS Control Module: Customer Interest ABS - Warning Lamp ON
NO: 05-02-94
GROUP: Brakes
DATE: Feb. 4, 1994
SUBJECT: ABS Warning Lamp Illuminated
MODELS: 1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT

PRIOR TO 1/17/94, MDH 01-17-XX.
SYMPTOM/CONDITION:
Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation.

With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation
will be fully functional. The lamp will stay illuminated until the next key cycle.

DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4

Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for
Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no
problems are found, proceed with the following repair procedure.

PARTS REQUIRED:
1 5269557 Controller, Antilock Brake (CAB)

REPAIR PROCEDURE:
This bulletin involves replacing the CAB with a revised part.

1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual
(Publication No. 81-270-5025), Pg. 5-89.

NOTE:
THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE

BENDIX PART NUMBER, SEE ILLUSTRATION.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-10-91 0.4 Hrs.
FAILURE CODE: P8 - New Part

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for ABS Control Module: > 050294 > Feb > 94 > ABS - Warning Lamp ON

ABS Control Module: All Technical Service Bulletins ABS - Warning Lamp ON
NO: 05-02-94
GROUP: Brakes
DATE: Feb. 4, 1994
SUBJECT: ABS Warning Lamp Illuminated
MODELS: 1995 (PL) Neon
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ABX-4 ANTILOCK BRAKES BUILT

PRIOR TO 1/17/94, MDH 01-17-XX.
SYMPTOM/CONDITION:
Illumination of ABS warning lamp without any prior symptoms of improper antilock brake operation.

With the lamp illuminated, the antilock brake feature is disabled and normal power brake operation
will be fully functional. The lamp will stay illuminated until the next key cycle.

DIAGNOSIS:
Using the Mopar Diagnostic System or the Scan Tool (DRB III), with the 1995 Bendix ABX-4

Antilock Brake System Diagnostic Procedure Manual (Publication No. 81-699-0420), check for
Diagnostic Trouble Codes (DTC). If a "Modulator Circuit" code is set, proceed to Test 2A. If no
problems are found, proceed with the following repair procedure.

PARTS REQUIRED:
1 5269557 Controller, Antilock Brake (CAB)

REPAIR PROCEDURE:
This bulletin involves replacing the CAB with a revised part.

1. Replace the CAB with revised P/N 5269557 as outlined in the 1995 Neon Service Manual
(Publication No. 81-270-5025), Pg. 5-89.

NOTE:
THE LABEL ON THE NEW CONTROLLER MUST HAVE THE LETTER "CE" BELOW THE

BENDIX PART NUMBER, SEE ILLUSTRATION.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No.
08-19-10-91 0.4 Hrs.
FAILURE CODE: P8 - New Part

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 25

ABS Control Module: Locations
ABS Controller
The controller is located in the passenger compartment, on the left kick panel.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 26

Controller Connector

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 27

ABS Control Module: Description and Operation
Fig 1 Controller Anti-Lock Brake System (CAB)
Fig 2 Controller Anti-Lock System (CAB)
The Controller, Antilock Brake (CAB) located under the lefthand side of the instrument panel is a

microprocessor device which monitors wheel speed and controls Antilock Brake System (ABS).
The CAB monitors the speed of each wheel through the signals generated at the wheel speed
sensors to determine if any wheel is beginning to lock. If any wheel lock is detected, the CAB
commands the Hydraulic Control Unit (HCU) to modulate pressure to 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 the ABS braking system. The CAB contains a
self-diagnostic program which will store system faults in a diagnostic program memory. There are
multiple fault 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 CAB memory even after the ignition has
been turned off.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Control
Module <--> [Electronic Brake Control Module] > Component Information > Technical Service Bulletins > Page 28

ABS Control Module: Service and Repair

1. Disconnect battery ground cable. 2. Disconnect wiring harness 60-way 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, torque 60-way connector retaining bolt to 38 inch lbs.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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 Interest Engine 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 indicator light (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

- 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control
Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 38

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 (allowing extra 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 and seal 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 assembly from 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 (allowing extra 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 and black 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 and seal 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 (one screw).

27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.)

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 tab sideways 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 the connector 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Radiator Cooling Fan Control
Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 39

- 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 (65 lb 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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 Bulletins Engine 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 indicator light (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

- 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 45

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 (allowing extra 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 and seal 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 assembly from 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 (allowing extra 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 and black 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 and seal 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 (one screw).

27. Reinstall the right radiator fan module (two screws). Torque to 7.2 Nm (65 lb. in.)

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 tab sideways 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 the connector 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Control Module: > 070197 > Mar > 97 > Engine Cooling Fan - Vehicle Overheating > Page 46

- 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 (65 lb 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

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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)

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 50

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
PDC cover for location. Check electrical terminals for corrosion and repair as necessary.

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Fan Relay <-->
[Radiator Cooling Fan Motor Relay] > Component Information > Locations > Page 51

Solid State Relay
Solid State Relay

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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 the Circuit 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
Wire Code Identification

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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

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 placed next 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 provides terminal numbering, circuit identification,
wire colors, and functions.

All connectors are viewed from the terminal end unless otherwise specified. To find the connector
location in the vehicle, refer to Connector Locations Index, which uses the connector identification
number from the wiring diagrams to provide a figure number reference.

Electrostatic Discharge (ESD) Sensitive Devices

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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

Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to

indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. 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: 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 of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut 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 the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.

Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct

amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.

Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular

circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.

CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.

WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.

WARNING:

Dodge Neon Workshop Manual (L4-2.0L SOHC (1995))
Dodge Workshop Manuals > 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

- 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. A MANUAL 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), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.

- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.

- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.

Symbols

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Fig.5 Symbol Identification
Various symbols are used throughout the Wiring Diagrams section. These symbols can be

identified by referring to the Symbol Identification chart.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the

wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index

information or the Alphabetic Index to Wiring Diagrams under Electrical

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Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.

Power Distribution Center Identification
Fig.21 Power Distribution Center Identification
For Power Distribution Center fuse and relay identification, refer to figure above. For additional

information on relay and fuse operation, refer to the wiring diagrams.

Wire Circuit and Gauge Identification
Fig.1 Wire Color Code Identification

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Fig.2 Wire Color Codes
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main

circuit, gauge of wire, and color. The color is shown as 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 will follow 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

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 six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.

5. Remove 1 inch of insulation from each wire on the harness side.
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.

7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.

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Wire Repair

9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).

10. Push the two ends of wire together until the strands of wire are close to the insulation (Example

2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 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 both

ends of the tubing.

14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches 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.

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Terminal Removal
Terminal Removal Using Special Tool

4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the

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

1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.

3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.

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5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.

Terminal Replacement

1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.

Connnector Locking Wedge Tab (Typical)

3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool

4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the

terminal from the connector.

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5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch 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 1 inch 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

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. Do not use acid core solder. 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.

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
1-1/2 inches behind the connector and 2 inches 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 6742 into the terminal end of the connector.

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Using Special Tool 6742

4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.

Wiring Repair
Wire Repair
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the

wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.

1. Disconnect the battery negative cable.

2. Remove 1 inch of insulation from each end of the wire.

3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.

4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).

5. Push the two ends of wire together until the strands of wire are close to the insulation (Example

2).

6. Twist the wires together (Example 3).

7. Solder the connection together using rosin core solder only. Do not use acid core solder.

8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both

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ends of the tubing.

9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.

10. Connect the battery and test all affected systems.

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Radiator Fan Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also

possible for a sticking component or relay to cause a problem. 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 Problems section.
Testing For Voltage
Testing For Voltage

1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the

appropriate test procedure.

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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

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 6 to 8 Inches 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.

Testing For Voltage Drop
Testing For Voltage Drop

1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.

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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.

These tools are listed and explained below.

- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.

WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED 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 to the 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 10 megohm or greater impedance.

- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.

CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.

Probing Tool

- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into 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 for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify

these add-on items 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.

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Radiator Fan Relay: Connector Views
Fig.21 Power Distribution Center Identification

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Power Distribution Center Front View

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Radiator Fan Relay: Electrical Diagrams
Dual Cooling Fans
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 presented for reference only.
Single Cooling Fan

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Air Conditioning-Heater (Part 1 Of 2)

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Air Conditioning-Heater (Part 2 Of 2)
The OE does not show a wiring diagram showing the dual fan option specifically until 1999 but the

dual fan option is mentioned. Additionally, the Radiator Fan Control is shown as a portion of the
A/C circuit and as a portion of the PCM circuit.

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Radiator Fan Relay: Description and Operation Radiator 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 in the Power Distribution Center (PDC) supply
voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a
30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the
PDC.

When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan.
The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F).

Whenever the PCM energizes the A/C compressor clutch it engages the fan. Also, to prevent
radiator steaming, the PCM energizes the radiator fan at idle following certain cold starts.

The radiator fan relay is located in the PDC. The inside top of the PDC cover has a label showing
relay and fuse location. See: Diagrams/Connector Views

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Radiator Fan Relay: Description and Operation Description of Trouble Codes

High Speed Fan Control Relay Circuit
NAME OF CODE:
High Speed Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.
SET CONDITION:
An open or shorted condition is detected in the high speed radiator fan relay control circuit.
THEORY OF OPERATION:
The high speed radiator fan relay controls the high speed operation of the radiator fan.
The relay is located in the power distribution center.
One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the

"RUN" position. The circuit is completed when the other side of the relay coil is grounded by the
powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant
temperature.

The PCM grounds the relay circuit when the engine coolant temperature is too high and removes
the ground when the temperature is acceptable

POSSIBLE CAUSES:

- Relay coil open or shorted

- Fused ignition switch output circuit open

- High speed radiator fan relay control circuit open or shorted

- Inoperative circuit driver in PCM
Low Speed Fan Control Relay Circuit
NAME OF CODE:
Low Speed Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.
SET CONDITION:
An open or shorted condition is detected in the low speed radiator fan relay control circuit.
THEORY OF OPERATION:
The low speed radiator fan relay controls the low speed operation of the radiator fan.
The relay is located in the power distribution center.
One side of the relay control coil is supplied with 12 volts when the ignition switch is turned to the

"RUN" position. The circuit is completed when the other side of the relay coil is grounded by the
powertrain control module (PCM). The PCM grounds the relay control circuit depending on coolant

temperature.
The PCM grounds the relay circuit when the engine coolant temperature is too high and removes

the ground when the temperature is acceptable
POSSIBLE CAUSES:

- Relay coil open or shorted

- Fused ignition switch output circuit open

- High speed radiator fan relay control circuit open or shorted

- Inoperative circuit driver in PCM
Rad Fan Control Relay Circuit
NAME OF CODE:
Rad Fan Control Relay Circuit
WHEN MONITORED:
With the ignition key ON and battery voltage greater than 10 volts.

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SET CONDITION:

An open or shorted condition is detected in the radiator fan relay control circuit.
THEORY OF OPERATION:
The radiator fan relay controls the operation of the radiator fan. The relay is located in the power

distribution center. One side of the relay control coil is supplied with 12 volts when the ignition
switch is turned to the "RUN" position. The circuit is completed when the other side of the relay coil
is grounded by the powertrain control module (PCM). The PCM grounds the relay control circuit
depending on coolant temperature. When the engine coolant temperature has reached the
maximum temperature parameter, the relay will be grounded. Conversely, when the engine coolant
temperature has acquired the minimum temperature parameter, the relay will remove the ground.

POSSIBLE CAUSES:

- Relay coil open or shorted

- Fused ignition switch output circuit open

- Low speed radiator fan relay control circuit open or shorted

- Inoperative circuit driver in powertrain control module

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Overview

Radiator Fan Relay: Initial Inspection and Diagnostic Overview

- Check the 30 Amp maxi fuse located in the Power Distribution center (PDC) for the radiator fan
motor(s).

- Check the 15 Amp fuse located in cavity 10 of the fuse block for radiator fan and A/C compressor
clutch relays.

- Check the 10 Amp micro fuse located in the power distribution center. When checking the A/C
compressor clutch relay,

- Check the 25 Amp fuse located in cavity 7 of the fuse block when checking blower motor
operation,

- Check the right headlamp ground located at the right fender side shield.

- Check the left headlamp ground located on the left side of the radiator closure panel.

- On vehicles equipped with A/C, check the refrigerant level. The system will not operate with a low
level of refrigerant.

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Cruise Control Relay: Description and Operation
NAME OF CODE:
Speed Control Power Relay Circuit
WHEN MONITORED:
With the ignition key ON, speed control switched ON, the SET button pressed and the brake pedal

released.
SET CONDITION:
The speed control power supply circuit is either open or shorted to ground.
THEORY OF OPERATION:
The PCM monitors the voltage drop across all speed control solenoids and the power supply

circuit.
POSSIBLE CAUSES:

- PCM misfire

- Open or shorted power supply circuit

- Failed dump solenoid (S/C servo)

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Compressor Clutch Relay: Locations
Fig.21 Power Distribution Center Identification
The relay is located in the Power Distribution Center.

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Condenser Fan Motor Relay: Locations
Fig.31 Power Distribution Center (PDC)

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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
PDC cover for location. Check electrical terminals for corrosion and repair as necessary.

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Solid State Relay
Solid State Relay

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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 in the Power Distribution Center (PDC) supply
voltage to the solenoid side and contact side of the relay. The radiator fan power circuit contains a
30 amp fuse between the buss bar in the PDC and the radiator fan relay. The fuse is located in the
PDC.

When engine coolant reaches a temperature of 99°C (210°F), the PCM energizes the radiator fan.
The PCM turns the fan OFF when coolant temperature drops to 93°C (199°F).

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 Fan
Relay/Diagrams/Connector Views