For 1990-2009 cars

# ELECTRICAL ACCESSORIES INTERMITTENTLY INOPERATIVE

#### SUBJECT: Electrical Accessories Intermittently Inoperative, MIL On and DTCs Set in PCM Memory, and/or Key Binds in RUN Position (Modify Ignition Lock Cylinder Tumbler) -------------------------------------------------------------------

#### MODELS: 1995-1997 Saturns -----------------

#### CONDITION:

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1. Electrical accessories may intermittently lose power after starting the vehicle or while vehicle is in operation. Some of the accessories that may lose power are: Radio, power windows, rear defog, DRL, cruise control, HVAC blower and/or A/C compressor.

Turning the ignition key Off and restarting the vehicle or "rocking" the ignition key in the RUN position may restore operation of these accessories.

2. The MIL (SERVICE ENGINE SOON telltale) on 1995 vehicles, or the Service (Wrench) telltale on 1996 or 1997 vehicles may be On during the loss of power. Possible diagnostic trouble codes (DTCs) are listed below.

Model Year DTCs Possible ---------- ---- --------

1995 26, 27 Voltage drop on quad driver circuits

1996-1997 P1640,Pl641 Low cruise module voltage P1650,Pl651 Low A/C relay voltage P0571,PO572 Low cruise brake switch voltage P1602 Loss of ABS module data

3. The ignition key may bind in the ignition lock cylinder at the RUN position. Condition may be compounded by the added weight on the key chain of additional keys and other items.

#### CAUSE

The tumbler in the 7th position (tumbler nearest the locking pin end) of the ignition lock cylinder may be binding as the ignition key is returned from Start to Run. This binding may result in poor or no electrical switch contact for ignition circuits 4 and/or 300.

#### CORRECTION

Modify the corner of the tumbler in the 7th position (position nearest the locking pin end) of the ignition lock cylinder according to the procedure in this bulletin.

#### PROCEDURE

1. Remove the ignition lock cylinder following the procedure in the appropriate year "Body/Repair Service Manual."

2. Remove the 7th position tumbler (tumbler nearest the locking pin, (D in illustration) from the lock cylinder.

3. Using a file, bevel the corner of the tumbler, opposite the spring tab as shown in the illustration. (There are four tumblers, numbered 1-4 that can be used in any of the seven positions, the #3 tumbler shown in illustration is typical.)

File the corner to the first notch at approximately a 30 degree angle. Smooth any burrs left by the filing operation and clean as necessary.

#### NOTICE: Care should be taken not to file any other comer of the tumbler. If any of the other corners are rounded during this operation, the security of the ignition lock could be reduced. If any other corners are rounded, replace tumbler and repeat step 3 of this bulletin.

4. Install the modified tumbler and spring in the lock cylinder. (Refer to the appropriate year "Body/Repair Service Manual.")

5. Oil the lock cylinder assembly with light oil or graphite lubricant and install into the ignition switch housing. (Refer to the appropriate year "Body/Repair Service Manual.")

#### NOTICE: Never use a silicone spray type lubricant. Silicone spray type lubricants wash away any existing oil from the lock cylinder and then evaporate. This leaves less lubricant in the lock cylinder, which may cause the lock cylinder to bind.

#### CLAIM INFORMATION:

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Labor Case Operation Type Description Code Time ---- ----------- ---------- -----

VW Modify Ignition Lock Cylinder T9726 0.4 hrs Tumbler

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.