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How to remove wires from inside CIS AAR plug

The wires to the AAR were worn and frayed to the point of almost being broken off completely right at the plug and I believe was causing some idle issues!

I'm trying to get the two metal wire contacts out of the plastic plug end so I can trim & re-solder the wires. Can anyone give me some tips here? I've tried a safety pin in one end while pulling on the wire and this doesn't seem to do anything, is there a trick or tool I don't know about?


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Cheers, Chris
1986 951

SOLD: 1975 Carrera / 965 tribute w/ 1989 3.3 turbo 8.5:1, custom Evergreen K27 7200, 964 cams, euro CIS, TEC1 dual plug, rarlyL8 headers & hooligan pipe.
Old 11-28-2016, 05:08 AM
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for most connectors, there is a tab that sticks down from the pin that is inserted into the connector that catches on the plastic part of the connector to keep it from sliding out, there is a tool that inserts into the front side of the connector that pushes the tab up so the pin can slide out, you may be able to find something that will slide in there to do the same thing,

I take it the connector is no longer attached to the wiring harness.
did you cut it off

you may be better of finding a new connector.
contact timmy2.

what kind of idling problem are you having?
the AAR on CIS cars does not work the same as an ICV on EFI cars, FYI,
although the name implies its a air regulator its really just a dummy valve that opens then closes once the engine is warm, the stays closed
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Last edited by T77911S; 11-28-2016 at 05:42 AM..
Old 11-28-2016, 05:40 AM
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Yes the wires are no longer connected to the plug, they were half way broken off then became completely broken off while trying to remove the connector inside the plug.

The idle was acting strange, i'd start the car cold and it would idle high and not come down, so I think the signal wasn't getting to the AAR to restrict the airflow and lower the idle.
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Cheers, Chris
1986 951

SOLD: 1975 Carrera / 965 tribute w/ 1989 3.3 turbo 8.5:1, custom Evergreen K27 7200, 964 cams, euro CIS, TEC1 dual plug, rarlyL8 headers & hooligan pipe.
Old 11-28-2016, 06:36 AM
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Yes Timmy2 will supply a new connector for $10 or so. He just sent me one for the notorious green wire from the distributor.

I think I'd go that route. There is a small metal tab that clicks into the plastic. You have to push the tab down from the side that you show in your photograph.

Here is a quick diagram I put together, if it helps at all

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Old 11-28-2016, 07:02 AM
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OK maybe i'll order from Timmy, I could feel something compressing when I put a pin into the one end but I could not get that little bugger to pull out!
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Cheers, Chris
1986 951

SOLD: 1975 Carrera / 965 tribute w/ 1989 3.3 turbo 8.5:1, custom Evergreen K27 7200, 964 cams, euro CIS, TEC1 dual plug, rarlyL8 headers & hooligan pipe.
Old 11-28-2016, 07:10 AM
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Quote:
Originally Posted by puddy View Post
The wires to the AAR were worn and frayed to the point of almost being broken off completely right at the plug and I believe was causing some idle issues!

I'm trying to get the two metal wire contacts out of the plastic plug end so I can trim & re-solder the wires. Can anyone give me some tips here? I've tried a safety pin in one end while pulling on the wire and this doesn't seem to do anything, is there a trick or tool I don't know about?

The wires push "forwards" from the back of the connector. When you make the connector you put the wires through, terminate them, then pull them back.

Get a new connector (Bosch EV-1) from DIY Autotune or similar.
Old 11-29-2016, 04:24 PM
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Ah they push forward, that should help me get them out. Thanks!!
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Cheers, Chris
1986 951

SOLD: 1975 Carrera / 965 tribute w/ 1989 3.3 turbo 8.5:1, custom Evergreen K27 7200, 964 cams, euro CIS, TEC1 dual plug, rarlyL8 headers & hooligan pipe.
Old 11-30-2016, 09:55 AM
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most pins come out the back.
it does look like is not enough room to put anything in thru the front.
if they do come out the front, you will need to push the tab down from the rear
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86 930 42kmiles [__] RUNNING:[__] NOT RUNNING: ____77 911S widebody: SOLD
88 BMW 325is 200K+ SOLD
05 BMW 330CI 130K:: [__] RUNNING: [__] NOT RUNNING:
08 VOLVO V70 190K:: [__] RUNNING: [__] NOT RUNNING:
90 B2200[__] RUNNING:[] NOT RUNNING:__2000 MER E320 WAGON [] WRECKED:[]RUNNING:
Old 11-30-2016, 10:51 AM
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Quote:
Originally Posted by T77911S View Post
most pins come out the back.
it does look like is not enough room to put anything in thru the front.
if they do come out the front, you will need to push the tab down from the rear
I just assembled a few of these, they push forward.

There's still a little locking springing piece.

I wouldn't worry about it anyway, just hack it off and install a new connector.

Old 11-30-2016, 03:32 PM
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