For 1990-2009 cars

# Ignition Key Will Not Fit in Cylinder Causing No Crank, No Start - keywords fit key lock start steering

Subject: | Ignition Key Will Not Fit In Cylinder Causing No Crank, No Start

Models: | 1992-1997 Saturn S-Series

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

### Condition/Concern:

Key blank P/N 21097940 has been changed to 21114554. The 21114554 key is approximately 1.4 mm shorter in length than 21097940. Additionally, the 21114554 has more squared off corners at the bottom of the plastic key head than the old P/N 21097940. Replacing a customer's key with 21114554 can possibly cause a no crank, no start condition. The shorter key with more squared off corners can possibly create an interference fit at the bottom two corners of the plastic key head and the Ignition Cylinder Bezel. This interference may result in complaints of the plastic key blank rubbing on the Ignition Cylinder Bezel and difficulty in rotating the key.

### Recommendation/Instructions:

The supplier of the 21114554 is updating the part to change the dimensions. In the interim, simply file and/or grind down the bottom two corners of the plastic key head about 1mm on both sides. This should allow the key to fully seat in the cylinder and allow its rotation to start the car.

This PI will be updated as soon as a replacement part is available.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.