1 04897717AA RFI Fan Filter Module
1 04897674AA Connector Package, Radiator Fan Motor

1. Record all radio presets.

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 - upper radiator mounts - battery thermo-guard -battery tray

4. Disconnect the left radiator fan motor. Remove and set aside the left radiator fanmodule assembly (two upper screws).

5. Disconnect the radiator fan motor feed wiring connector from the right fan motor RFI filterassembly (Illustration).

6. Remove the entire right radiator fan module assembly (two screws). Place the fanmodule 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 6inches 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 oppositeorder as you did on the vehicle wire harness side (allowing extra length for solderedconnections.) Be sure that the overall length of the new repaired wiring is the same asthe 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 endstogether. 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 centereach 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 tubingwith tape.

RFI Fan Filter Module (On Bench):

17. Cut off the existing right motor wiring from the RFI filter module assy, and remove aboutfour 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 theopposite order as you did on the motor wiring side (allowing extra length for solderedconnections.) Be sure that the overall length of the new repaired wiring is the same asthe original.

21. Strip an inch of insulation off the end of each wire on the new RFI filter modulewiring harness.

22. Slide a piece of heat shrink tubing onto each wire of the RFI filter module wiringharness wiring.

23. Connect each RFI filter module wiring harness end to each motor wire end bytwisting the ends together. Be sure to match colors -- blue to blue and black toblack.

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 centereach splice inside the tubing. Heat the tubing to shrink and seal the splice. Use theapproved air heat gun only.

26. Tape the wire harness over splices up to 1 1/2" behind the back of the RFI filtermodule 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 inuntil the connector snaps into place. Slide the red tab sideways to lock the connectorinto place.

29. Re-install the left radiator fan module (two screws). Torque to 7.2 Nm (65 lb in.). Routethe 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 (PublicationNumber 81-270-7025) on Page 8A-9. Install: - upper radiator mounts - battery - radiator-to battery strut - battery tray - battery thermo-guard

31. Reconnect the body ground cable and battery cables. Torque body ground cable screwto 4.0 Nm (35 Ib-in.) and battery terminals to 7.2 Nm (65 lb in.). Verify proper fanoperation.

32. Reset all radio presets recorded in step 1.