Engine Cooling Fan - Vehicle Overheating
NO: 07-01-97GROUP: 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 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
- 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