I just noticed some previously unnoticed cracks in the wiring towards the end of the CKP connector. Figure I'll just cut the last few inches off and splice in new wire. Is there a way to remove the pins without destroying the connector? Can the pins be found at an auto parts store?

 

Rather than replacing the wire, with cracked insulation on the individual conductors, consider using a liquid insulation that dries to a plastic. See Liquid Electrical Tape & Spray Electrical Insulation – Plasti Dip. They carry this sort of thing in the electrical aisle at Home Depot. Once good, then wrap whole thing with a higher temp tape (also sold there). Most connectors have to be matched from same factory, there are more types and sizes of pins than pages in the RAVE.

 

I fixed my cruise with Liquid Tape almost 5 yrs ago, still works.

 

NAPA sells the new pigtail end. You can just splice it back where the harness wire is good.

 

Napa has two versions. See attached page. NAPA AUTO PARTS And there's alway duct tape to make a temp fix and see if you can slam the door on this gremlin.

 

Thanks guys. I doctored it up real nice with liquid electrical tape, then high temp electrical, then wire loom, and finally a reflective heat shield sleeve.

 

But your problem continues?