For 1990-2009 cars

# SMU - SECTION 8C - NEW IGNITION SWITCH LOCK CYLINDER

REVISION: 04/25/97

THIS BULLETIN IS BEING REVISED TO ADD AN "IMPORTANT" STATEMENT TO STEP 9 REGARDING THE PROCEDURE IF AN IGNITION KEY OR KEY CODE IS NOT AVAILABLE. PLEASE DISCARD CORPORATE BULLETIN NUMBER 63-83-16 (SECTION 8 - CHASSIS/BODY ELECTRICAL). ----------------------------------------------------------------------

#### SUBJECT: SERVICE MANUAL UPDATE - SECTION 8C - NEW IGNITION SWITCH LOCK CYLINDER REMOVE/INSTALL PROCEDURE

#### MODELS: 1997 CHEVROLET MALIBU 1997 OLDSMOBILE CUTLASS

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THIS BULLETIN IS BEING ISSUED TO ADD THE REMOVE/INSTALL PROCEDURE FOR THE IGNITION SWITCH LOCK CYLINDER IN SECTION 8C OF THE SERVICE MANUAL (GMP/97-LN-1). PLEASE INSERT THE FOLLOWING INFORMATION IN THE INSTRUMENT PANEL, GAUGES AND CONSOLE SECTION OF THE SERVICE MANUAL.

IGNITION SWITCH LOCK CYLINDER (REFER TO FIGURE 26 IN THE SERVICE MANUAL)

THE IGNITION KEY IS NEEDED TO PROPERLY REMOVE THE IGNITION SWITCH LOCK CYLINDER FROM THE IGNITION SWITCH. IF THE IGNITION KEY OR KEY CODE IS UNAVAILABLE, FOLLOW THE INSTRUCTIONS IN THE "IMPORTANT" STATEMENT AFTER STEP 9 OF "REMOVE OR DISCONNECT".

#### PROCEDURE:

REMOVE OR DISCONNECT

1. NEGATIVE BATTERY CABLE.

2. DISABLE SIR SYSTEM. REFER TO DISABLING SIR IN SECTION 8C OF THE SERVICE MANUAL.

3. IGNITION SWITCH TRIM RING.

4. ACCESSORY TRIM PLATE. REFER TO ACCESSORY TRIM PLATE IN SECTION 8C OF THE SERVICE MANUAL.

5. UPPER STEERING COLUMN COVER. REFER TO STEERING COLUMN COVERS IN STEERING WHEEL AND COLUMN - ON VEHICLE SERVICE IN SECTION 3F OF THE SERVICE MANUAL.

6. INSTRUMENT CLUSTER TRIM PLATE. REFER TO CLUSTER TRIM PLATE IN SECTION 8C OF THE SERVICE MANUAL.

7. INSTRUMENT CLUSTER. REFER TO INSTRUMENT PANEL CLUSTER IN SECTION 8C OF THE SERVICE MANUAL.

8. IGNITION SWITCH ASSEMBLY BOLTS.

9. IGNITION SWITCH ASSEMBLY ELECTRICAL CONNECTORS.

#### IMPORTANT:

IF THE IGNITION KEY OR KEY CODE IS NOT AVAILABLE OR THE IGNITION CYLINDER WILL NOT ROTATE, USE THE FOLLOWING PROCEDURE TO DRILL A HOLE IN THE SWITCH AND REMOVE THE CYLINDER. IF "PASS LOCK" EQUIPPED, THERE IS NO NEED TO DISCONNECT PRIOR TO CYLINDER REMOVAL.

A. LOCATE THE SURFACE FOR THE CYLINDER RELEASE BUTTON ON THE PLASTIC IGNITION SWITCH HOUSING AND CENTER PUNCH A LOCATION ON THE "RIB" APPROXIMATELY 3/8" REARWARD (TOWARD THE KEY ENTRY END) FROM THE CYLINDER RELEASE BUTTON, SEE FIGURE 1.

B. USING A 1/8" DRILL BIT, CAREFULLY DRILL A PILOT HOLE THROUGH THE PLASTIC HOUSING ONLY.

C. USING A 9/32" DRILL BIT, CAREFULLY DRILL A LARGER HOLE AT THE PILOT LOCATION AND SLIGHTLY INTO THE LOCK CYLINDER SURFACE TO BREAK THE RELEASE BUTTON RETAINING SPRING.

D. REMOVE PORTIONS OF THE BROKEN SPRING FROM THE HOLE USING A SMALL PAIR OF NEEDLE NOSE PLIERS (OR OTHER SUITABLE TOOL) AND TURN SWITCH OVER TO SHAKE OUT THE RELEASE BUTTON.

E. GRASP THE LOCK CYLINDER, REMOVE IT FROM THE SWITCH BODY AND CHECK THE CYLINDER CODE, SEE FIGURE 2.

F. REMOVE ANY PLASTIC "FLASH" FROM THE DRILLING OPERATIONS AND, USING COMPRESSED AIR, BLOW OUT THE IGNITION SWITCH ASSEMBLY.

G. INSTALL THE NEW CYLINDER BY ROTATING BOTH THE CYLINDER AND IGNITION SWITCH TO THE "ON" POSITION AND PUSHING THE CYLINDER INTO THE SWITCH. IT MAY BE NECESSARY TO DEPRESS THE RELEASE BUTTON SLIGHTLY AS IT PASSES BY THE 9/32" HOLE PREVIOUSLY DRILLED IN THE HOUSING.

10. IGNITION LOCK CABLE FROM IGNITION SWITCH ASSEMBLY.

11. IGNITION SWITCH ASSEMBLY FROM VEHICLE.

12. INSERT KEY INTO IGNITION SWITCH CYLINDER AND ROTATE TO THE RUN POSITION.

13. PRESS THE CYLINDER RELEASE PLUNGER (LOCATED AT THE 4 O'CLOCK POSITION) ON THE IGNITION SWITCH ASSEMBLY.

14. PULL CYLINDER FROM IGNITION SWITCH WITH KEY.

INSTALL OR CONNECT

1. CYLINDER TO IGNITION SWITCH, VERIFY ENGAGEMENT AND OPERATION WITH KEY.

2. IGNITION SWITCH ASSEMBLY TO VEHICLE.

3. IGNITION LOCK CABLE TO IGNITION SWITCH ASSEMBLY, VERIFY ENGAGEMENT.

4. IGNITION SWITCH ASSEMBLY ELECTRICAL CONNECTORS, VERIFY ENGAGEMENT.

5. IGNITION SWITCH ASSEMBLY BOLTS.

6. INSTRUMENT CLUSTER.

7. INSTRUMENT CLUSTER TRIM PLATE.

8. UPPER STEERING COLUMN COVER.

9. ACCESSORY TRIM PLATE.

10. IGNITION SWITCH TRIM RING.

11. ENABLE SIR SYSTEM. REFER TO ENABLING SIR IN SECTION 8C OF THE SERVICE MANUAL.

12. NEGATIVE BATTERY CABLE.

#### WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION NUMBER DESCRIPTION LABOR TIME =============== =========== ==========

E7200 CYLINDER, IGNITION LOCK - USE PUBLISHED R & R OR REPLACE LABOR OPERATION TIME

FIGURES: 02 ATTACHMENTS: 00

FIGURE 1 - INSTRUMENT PANEL MOUNTED CYLINDER, HOLE LOCATION

FIGURE 2 - CYLINDER COMPONENTS AND KEY CODE LOCATIONS (SIDE VIEW OF LOCK CYLINDER ASSEMBLY) 1. TUMBLERS 2. KEY CODE 3. POSITIONING TAB 4. LOCKING TAB 5. SIDE BAR

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

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