Engine Harness - Intermittent Operation of Circuits
NO: 08-02-96GROUP: Electrical
DATE: Jan. 26, 1996
SUBJECT:
Intermittent Operation Of Circuits In Engine Wiring Harness
MODELS:
1996 (PL) Neon
NOTE:
This bulletin applies to vehicles with a 3 (TOLUCA) in the first position of the Vehicle Identification Number, built prior to November 22, 1995 (MDH 11-22-XX).
SYMPTOM/CONDITION:
Intermittent operation of any circuit in the engine wiring harness, such as vehicle cranking, A/C clutch, idle air control, fuel gauge operation, and MIL light illumination may be the result of a mis-routed engine harness.
INSPECTION/ROUTING PROCEDURE:
This bulletin involves the inspection and correction of the engine wiring harness routing if needed.
INSPECTION PROCEDURE:
1. Open the hood and inspect the engine wiring harness take-outs to the 40-way connector on the PCM and the two 10-way connections at the PDC. The 10-way take-outs must route over the heater hoses and into the clip located on the inboard side of the PDC. The PCM 40-way take-out must route over the heater hoses with the locator snapped into the vehicle speed control bracket or transmission mount per Figure 1
2. If the harness is properly routed and installed in the clip inboard of the PDC, no further action is required.
3. If the harness is improperly routed, proceed with the routing procedure.
ROUTING PROCEDURE:
1. Record preset radio station settings and disconnect the battery.
2. Raise the PDC off the bracket to allow access to the engine wiring. Disconnect the two 10-way connectors from the PDC and the engine 40-way connector from the PCM.
3. Remove the air intake tube from the throttle body and the air cleaner assembly.
4. Remove the wiring harness.
5. Inspect the wiring for damage and repair as needed. Any repairs should be recorded and claimed using the appropriate labor operation number from the Labor Operation Manual.
6. Route the engine harness over the heater hoses, and under the speed control throttle cable and the main throttle cable.
7. Reconnect the two 10-ways to the underside of the PDC. These connectors have a connector position assurance (CPA) feature which provides for a fully mated, positive engagement of the connector. When installing the connectors, return the red slide to its original position after engaging it into its mating connector. If the red slider will not return to its original position, the connector is not fully engaged. See Figure 2
8. Route the harness through the molded-in clip on the inboard end of the PDC. Snap the PDC into position.
9. Snap the locator on the 40-way bundle to the transmission mount or vehicle speed control bracket as appropriate. Reconnect the 40-way to the PCM.
10. Install the air intake tube.
11. After a thorough visual inspection to insure routing is now in proper position reconnect the battery. Figure 1
12. Set the preset radio stations.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-67-90 0.2 Hrs.
Inspect Harness - Harness Routed Properly 1996 (PL)
Labor Operation No: 08-90-67-91 0.3 Hrs.
Inspect Harness - Harness Mis-routed- 1996 (PL)
Correct Harness Routing
FAILURE CODE: 9X - Routed Improperly