SUBJECT: Safety Recall #614 ­­ Powertrain Control Module (PCM), and Rear Brake Hose Mounting Bracket Screws
NO: 614
GROUP: RECALL
DATE: June. 1994
MODELS:
1995 Model Year Dodge/Plymouth Neon (PL­Body) Vehicles Built Through February 1, 1994, (MDH 02­01­XX)
SYMPTOM/CONDITION:
DIAGNOSIS:
DISCUSSION:

Reference: February 4, 1994 and February 9, 1994, Electronic Mail (DMAIL) Messages on this subject.

The referenced DMAIL messages instructed dealers to perform the following repairs. Notification letters are now being mailed to owners of involved vehicles for which the recall service has not yet been completed according to current records.

The Powertrain Control Module (PCM) may ingest moisture and cause several related malfunctions, including engine die­out, no­start and check engine light coming on. To correct this condition, the PCM must be replaced. Also, the four rear brake flex hose mounting bracket screws must be replaced, the positive battery bolt/stud will be replaced, two PCM mounting screws will be replaced and the VECI label will be checked and replaced if necessary.

IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.

Details of this service action are explained in the following sections.

Service Procedure Videotape

No videotape of the service procedure for this recall will be provided.

Dealer Notification & Vehicle List

Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the incomplete involved vehicles by Certified Mail.

Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information.

The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence.

Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

All dealers: Each Dodge and Chrysler­Plymouth dealer will receive a copy of this dealer recall notification letter by first class mail.

DIAL System Function 70

All involved vehicles were entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.

Parts

Important: Our records indicate that most of the involved vehicles have been serviced as a result of the previous DMAIL messages. Therefore, no parts will be distributed initially to dealers. Dealers are requested to order Powertrain Control Module packages, Recall PN C3906141, C3906142, C3906143 or C3906144, only to support scheduled repairs.

Due to the different transmission and emissions configurations of the involved vehicles, four parts packages are required for this recall. The Vehicle VIN List provided to each involved dealer includes a part code number which identifies the required parts package for each VIN. This part code is located in the third column of the VIN list and is identified by the "P" column header. The following listing identifies the applicable parts package represented by each number.

Parts Package Application

TRANSMISSION (Sales Code) EMISSION PACKAGE (Sales Code) RECALL PACKAGE PART NUMBER VIN LIST PART CODE ,
Manual (DD5) California (NAE) C3906141 1
High Altitude(NAF) C390614 1
Manual (DD5) Federal Sea Level (NAA) C3906142 2
Automatic (DGA) California (NAE) C3906143 3
High Altitude (NAF) C3906143 3
Automatic (DGA) Federal Sea Level(NAA) C39061444 4

Each parts package contains the following components:

Quantity Description
1 Powertrain Control Module (PCM)
1 Positive Battery Terminal Bolt/Stud
1 Vehicle Emissions Control Information (VECI) Label
2 PCM Mounting Screws
4 Rear Brake Hose Mounting Bracket Screws

Owner Notification and Service Scheduling

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Service Procedure

A. PCM and Battery Bolt/Stud Replacement

1. With the ignition key in the OFF position, disconnect the negative battery terminal.

Note: To ensure customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset the electronic memory when you have completed the service procedure.

2. Disconnect the positive battery terminal, then remove and discard the bolt/stud assembly. Install the new positive battery terminal bolt/stud and torque starter cable eyelet nut to 105 in­lb. (12 Nm) (Figure 1).

Note: Align the flats of the starter cable eyelet terminal with flats on bolt. Do not reinstall battery terminal onto battery post until step 11.

3. Depress two release tabs at front of Power Distribution Center (PDC) and set PDC aside for access to Powertrain Control Module (PCM) and wiring (Figure 2)

4. Disconnect PCM 60­way wiring connector.

5. Remove the three PCM mounting screws, disconnect wiring take­out clip and remove PCM with bracket assembly (Figure 3).

6. Route excess 60­way PCM wiring under the front engine compartment wiring harness so that the 60­way wiring forms a downward loop from the PCM (Figure 4).

7. Install the PCM 60­way wiring connector onto the new PCM assembly and torque bolt to 35 in lbs. (4 N m) (new PCM installation bracket positions 60way connector so that it faces rearward).

8. Install the two provided screws into the rear PCM bracket mounting holes and tighten securely.

9. Center punch and drill an 1/8 inch hole in sheet metal at the forward PCM bracket hole location, then coat exposed metal with primer. Install one of the old (pointed) mounting screws in the drilled hole and tighten securely (Figure 5).

Caution: To avoid drilling into the windshield washer bottle, tape drill bit 1/4 inch from the end.

10. Reinstall PDC and lock two release tabs in place.

11. Reinstall positive, then negative battery terminals.

B. Rear Brake Hose Mounting Bracket Screw Replacement

1. Locate the brake flex hose mounting bracket and replace all four screws (2 per side) with the screws provided (Figure 6). Torque the provided screws to 105 in­lbs. (12 Nm).

C. VECI Label Inspection and Installation

Inspect the part number of the Vehicle Emissions Control Information (VECI) label attached to the under­side of the hood and install a new label over the existing one ONLY AS DIRECTED BELOW:

RECALL PCM PACKAGE PN WITH VECI LABEL PN REQUIRED ACTION
C3906141 OR C3906143 4669744 ­­­> 0K­No Action Required
4669749 ­­­ > 0 K­No Action Required
4669748 ­­­> Install Label PN 4669749
C3906142 OR C3906144 4669748 ­­­> 0K­No Action Required
4669749 ­­­> Install Label PN 4669748

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

Labor Operation Number Time Allowance
Replace PCM, brake hose mounting screws, battery bolt/stud and, if necessary, replace VECI label - 08614182 0.5 Hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

If any of the following services were provided on sold vehicles, submit a separate claim and use labor operation number 95051950 for the actual expense incurred in the special service section of the claim:

· Pick up and delivery of vehicle Loaner expense
· Wash · Gas

Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions.

Parts Return

Not required.

Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre­addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation 429­10­04
P.O. Box 1919 Detroit, Michigan 48231­1 919

Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.