SUBJECT: Sags/Hesitation/Stumble, Harsh A/C Engagement, Erroneous DTC $76, Or Headlamp Flicker
NO: 8-23-98 Rev. A
GROUP: Vehicle Performance
DATE: Aug. 21, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-23-98 DATED JUL. 17,1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE TOLUCA PART NUMBERS LISTED WERE INADVERTENTLY LEFT OUT OF THE SUPERSEDENCE LIST FOR THE FLASH UPDATE. ALL REVISIONS ARE HIGHLIGHTED WITH "ASTERISKS".
MODELS: 1998 (PL) Neon
NOTE: PRIOR TO PERFORMING THIS BULLETIN, RECALL 769 MUST BE COMPLETED ON ALL APPLICABLE TOLUCA BUILT (T IN 11 TH VIN POSITION) VEHICLES.
SYMPTOM/CONDITION:

1 Sags, hesitation, or stumble after a cold start in ambient temperatures of -7 to 30C (20 - 86 F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index.

2. Harsh A/C engagement or A/C bump.

3. Erroneous DTC $76 - FUEL SYSTEM RICH in high ambient temperatures (SOHC ATX Only).

4. Headlamp flicker when radiator fan cycles.

DIAGNOSIS:Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB 1110) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC $76 is present or any of the other symptoms have been experienced, perform the Repair Procedure.

NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE  REPLACED CONTROLLERS AS NECESSARY.
 

EQUIPMENT/PARTS REQUIRED:

1 CH6000 Scan Tool (DRB 111)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J 1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
AR(1) 05293157AA Jumper, Radiator Fan (Toluca Built Only)
AR(2) 04641780 Tie Straps (Toluca Built Only)

NOTE: THE MDS AND DRB 111 ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE **1167** OR HIGHER MUST BE INSTALLED.

REPAIR PROCEDURE:

This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all models and verifying build range, PCM p/n and presence of jumper p/n 05293157AA for Toluca built vehicles.

NOTE: ALL TOLUCA BUILT VEHICLES (T IN ELEVENTH VIN POSITION) BUILT BETWEEN SEP. 11, 1997 AND OCT. 16,1997 (MDH 0911XX AND 1016XX) WITH THE FOLLOWING PCM PART NUMBERS MUST BE CHECKED FOR THE PRESENCE OF A JUMPER HARNESS INSTALLED IN THE RADIATOR FAN CIRCUIT. IF THE JUMPER IS NOT PRESENT, IT MUST BE INSTALLED PRIOR TO PERFORMING THE REPROGRAMMING PROCEDURE.

2.01- MPI SOHC FED MTX 5293148AA
2.01- MPI SOHC CAL MTX 5293141AA
2.01- MPI SOHC FED/CAL MTX (ACR) 5293142AA
2.01- MPI SOHC FED (ATX) 5293144AA
2.01- MPI SOHC CAL (LEV) ATX 5293145AA
2.01- MPI DOHC FED MTX 5293152AA
2.01- MPI DOHC CAL MTX 5293149AA
2.01- MPI DOHC FED/CAL MTX (ACR) 5293150AA
2.01- MPI DOHC FED ATX 5293153AA
2.01- MPI DOHC CAL ATX 5293151AA
JUMPER HARNESS PROCEDURES - AS REQUIRED

1 . Raise the hood and disconnect the negative battery cable.

2. Raise the vehicle on a suitable hoist.
3. Locate the left (drivers' side) black fan motor connector. Retract the red latch on the two-way female connector, depress the thumb latch, and disconnect 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 the fan is not damaged.

 4. Pry out the two push retainers located on the lower radiator enclosure reinforcement.

5. Install the jumper wire assembly (p/n 05293157AA) 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 the vehicle. 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 the locked 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. If the original wiring to the fan was clipped into the fan support, snap the new clip on the jumper into the  same hole.

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.

REPROGRAMMING PROCEDURES

1. Connect the MDS (Mopar Diagnostic System) and DRB 111 (Scan Tool) to the vehicle and power them up.

2. Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB 111 MAIN MENU Screen.

3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB 1110 on the MDS, then press NEXT MENU.

6. Follow the steps presented on the MDS and DRB III" which will allow the DRB 111  to obtain the current part number of the PCM.

7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.   If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.

8. The MDS and DRB 1110 will prompt for any operator action needed during the remainder of the programming process.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.

9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 3). Attach the label to the PCM and cover the label with the clear plastic overlay.

10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 4).  

POLICY: Reimbursable within the provisions of the warranty.