Headlamps - Flickering When A/C System Cycles
NO: 08-26-96 Rev. AGROUP: Electrical
DATE: Nov. 15, 1996
SUBJECT:
Headlamp Flicker
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-26-96 DATED AUGUST 30,1996 WHICH SHOULD BE REMOVED FROM YOUR FILES. THE JEEP CHEROKEE SECTION 15 BEING DELETED DUE TO SOME UNRELATED ELECTRICAL COMPLICATIONS. ALL UNINSTALLED CHEROKEE PARTS PACKAGES SHOULD BE RETURNED USING ESTABLISHED PARTS RETURN PROCEDURES.
MODELS:
1995 - 1996 (PL) Neon
SYMPTOM/CONDITION:
Head lamps "flicker" with head lamps on when radiator fan(s) or A/C system "cycles" on.
PARTS REQUIRED:
1 4856386 Headlamp Flicker Package (Neon)
Package Contains
1 Solid State Relay
1 PWM Module
1 Wiring Overlay Harness
2 Solid State Relay Attaching Screws
AR 6015756 Tie Straps
REPAIR PROCEDURE:
This bulletin involves installing a solid state relay in the radiator fan circuit and a control module in the PDC replacing the radiator fan relay.
NEON REPAIR PROCEDURE:
1. Record the radio preset radio stations. Disconnect and isolate the battery negative cable.
2. Raise the vehicle on a hoist to gain access to the left lower cross member area.
3. If the vehicle is equipped with speed control, remove the two lower screws retaining the splash shield and fold it out of the way.
4. Locate a position on the lower cross member 2-3/4" (70 mm) from the left edge and 2" (50 mm) up from the lower edge and drill a 1/4" (8 mm) hole. This hole will be used for the guide pin on the solid state relay. Figure 1.
5. Position the solid state relay against the cross member with the guide pin in the hole with the relay parallel to the cross member. Scribe the cross member through the upper and lower mounting holes on the relay. Remove the relay and drill two 9/64" (3.8 mm) holes in the cross member.
6. Mount the solid state relay on the cross member using the two attaching screws in the parts package.
NOTE:
THE LOCATING PIN ON THE SOLID STATE RELAY MUST BE FULLY INSERTED INTO THE GUIDE PIN HOLE ALLOWING THE RELAY TO BE FLUSH TO THE CROSS MEMBER, OTHERWISE DAMAGE TO THE RELAY MAY OCCUR.
7. Disconnect the wiring connector from the radiator fan module.
CAUTION:
ON DUAL FAN MODULES, CARE SHOULD BE TAKEN TO INSURE THAT THE WIRING CONNECTION IS NOT MADE TO THE 2ND FAN MOTOR.
8. Connect the "Y" end of the wiring overlay harness from the parts package between the radiator fan module and the vehicle wiring harness. Connect the remaining connector to the solid state relay. Use tie straps as necessary to support the wiring overlay harness.
9. Route the single red wire from the wiring overlay harness to the Power Distribution Center (PDC) by following the vehicle wiring harness routing up the left side rail.
10. Install the splash shield back on the vehicle, if so equipped.
11. With the vehicle on the ground, remove the cover from the PDC and remove the starter relay, radiator fan relay and the A/C Clutch and Fog Lamp relays, if so equipped. Pry up on and remove the orange terminal locking strip.
12. Release the PDC from the battery tray by unlatching the two tabs along the front edge. Rotate the PDC over toward the left fender. Remove the plastic cover from the bottom of the PDC to allow access to the connectors.
13. Insert the terminal of the red wire from the wiring overlay harness into cavity # 39 for the Neon. This cavity is in the center of the radiator fan relay socket. Figure 2
14. Route the red wire along with the rest of the wire bundle and replace the plastic cover on the bottom of the PDC.
15. Rotate the PDC back into place on the battery tray
16. Install the orange terminal locking strip back into the PDC and install the relays removed previously with the exception of the radiator fan relay.
17. Install the PWM module from the parts package into the radiator fan relay location in the PDC. Install the cover back on the PDC. Figure 3.
18. Connect the battery and reset the radio stations and clock.
19. Start the engine and with the A/C-Heater system in the defrost or A/C mode and recirculation mode and verify that the radiator fan(s) turn on.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-65-12-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment