Early Turbo Dodge (87 and earlier)
AIS Motor/Sensor Rebuild Tips

This guide will help you to take apart and re-assemble the early “log style” AIS (Air Idle Control) valve that was used on the turbo dodge cars from 1984-1987. Often, trouble with idle control can be traced back to the control valve and the cause is sometimes due to the valve being either clogged with debris or the internal planetary gears being gummed up with old grease.  In either case, a disassembly, cleaning, lubrication and reassembly can sometimes resolve the idel control issue.

STEP 1:
First you remove the clamp over the mid portion of the AIS motor and slowly pull out the motor with slight twisting motion.

STEP 2:
Next is a picture of the AIS air control valve portion with the three planetary gears being shown still in place. You should make note that there are 3 alignment pins on the case of the planetary gear loading plate, these align with the holes in the motor as a index and lock the assembly to prevent spinning of the case during operation.

STEP 3:
Next you can remove the planetary gear assembly, and be sure to make note of the different colors. The gears have also a top and a bottom side, the top of the gear as we see it here has four injection marks on top but only two on the bottom side. Please note the white ring has a small triangle protrusion near the gray gear, if this is not located at this spot the assembly will be off center during the final assembly.

STEP 4:
Disassemble the planetary gear assembly and clean it well with something like brake and parts cleaner. Once all the parts are clean we can start to assemble

STEP 5:
Place the two ring clip into the groove while pushing down the center of the assembly. It’s good to place the openings of the clip 180 degrees from each other.

STEP 6:
Finally you should place the AIS air control valve portion on the top.

STEP 7:
Assemble planetary gears as shown on the right. Remember to place the gray gear on the post with the outward triangle on the white ring

STEP 8:
Place the planetary gear assembly on top of the AIS control motor.

STEP 9:
Now you can place the planetary valve assembly on top and slowly drop the outer plastic casing from the top. Watch the alignment of the valve as the unit goes together. Secure with clamp and test AIS operation when attached to car connector. Here is how you do that:

After you reconnected your battery turn the ignition on but do not start! The valve should move. Turn off ignition. Check the quality of the o-rings that are on the outside of the valve, they are there to prevent additional air from entering the intake.  and replace if necessary.

Remember to check base idle settings after the AIS is installed.

CREDITS AND ACKNOWLEDGMENTS

This information was provided in part by a post from the turbo Dodge enthusiast community forum turbo-mopar.com.  We encourage you to visit their web site forum and to become a member with a paid membership to support the forum and to help sustain the turbo Dodge enthusiast community.  Be an active paid member of the community!