For 1990-2009 cars

# Service Information for New 1991-1997 First Design Key (Square Head) Ignition Lock Cylinders

Subject: | Service Information for New 1991 -- 1997 First Design Key (Square Head) Ignition Lock Cylinders. This Bulletin Updates the Ignition Lock Cylinder Coding Procedure in the 98 -- 99 Body repair Service Manual.

Models: | 1991 -- 1996 and 1997 interim Saturns with first design key (square head)

### Purpose

Due to a design change in the service replacement parts for 1991 -- 1996 and 1997 first design key (square head) ignition lock cylinders, the ignition lock cylinder packages, ignition lock cylinder components parts, and the 1991 -- 1999 Saturn Key Code Manual need to be updated.

All 1991 -- 1997 first design key (square head) service replacement ignition lock cylinders will now have a sidebar and six tumblers. The sidebar is not serviced separately . The tumblers, tumbler springs, bezel, ignition pin, and ignition pin spring are all unique to the new design and are used only for service replacement of 1991 -- 1997 first design key (square head) ignition lock cylinders--not for 1998-1999 Saturns.

Important: All first design key (square head) ignition lock cylinders in need of repair or coding should be serviced with second design service replacement ignition lock cylinder packages (refer to parts list) and coded using second design ignition lock cylinder components parts.

In addition, the 1991 -- 1999 Saturn Key Code Manual must be updated to reflect the change to a 6-tumbler ignition lock cylinder design. Please make the following column heading changes in the "1991- 1997 Saturn Key Code List" section of the 1991 -- 1997 Saturn Key Code Manual: Master Key 91-97 INT IGN DOOR R/CMPT Also, cut two new keys (P/N 21097940) for all customers using the "Master Key " code. Some customer with 1991- 1994 vehicles may have the shorter version of the first design key (P/N 21097305) which will rub on the bezel of the 1991 -- 1994 second design ignition lock cylinder. (Reference Technical Bulletin 94 -- T -- 50 for key length change) After cutting new keys, scrape off any burrs and perform a functional check of all vehicle lock cylinders with new keys. The following pages provide the ignition lock cylinder coding procedure. Copies of this bulletin should be made and inserted in the "General Information" section of all 98-99 Body Repair Service Manuals before the "Ignition Lock Cylinder Coding -- All" procedure.

### Procedure

1. Remove shroud fasteners (5.5 mm hex head) and remove steering column upper shroud panel.
2. Insert key into ignition lock cylinder and rotate to ACC position.
3. Depress the square locking button on the top of ignition module assembly from ignition module housing.
4. Remove lock cylinder bezel by carefully prying from lock cylinder with thin bladed screwdriver.
5. Insert key into ignition lock cylinder assembly and depress ignition locking pin using a thin bladed screwdriver.
6. Rotate cylinder and remove ignition locking pin.
7. Remove cylinder from case.
8. Push tumblers out of lock cylinder using a thin bladed screwdriver.

Important: Ignition lock cylinder reads key cut positions 1 through 6.

9. Select the correct tumblers for the desired code by the number stamped on the tumbler.

Important: Make sure the tumbler springs are in place before installing tumblers.

Important: The new design tumblers do not lock the ignition lock cylinder. The tumblers may fall out of the ignition lock cylinder without the key installed.

10. Install tumblers by applying downward pressure. If the tumblers are difficult to install, make sure that the sidebar is not crooked. Push down on the raised end of sidebar to level it.
11. After all tumblers are installed, depress all six tumblers and sidebar will be flush with cylinder with key inserted.

Important: Actuator blade within ignition module housing must be in the ACC position to install lock cylinder assembly. If rotated, replace it to the ACC position using needle nose pliers.

12. Oil lock set with a light oil or graphite lubricant (as needed) and install cylinder into case.
13. Install ignition locking spring and pin.

Depress pin and rotate cylinder to engage.

14. Remove key and install lock cylinder bezel.
15. Insert key and reverse steps 1 through 3.

#### Parts Requirements

21171128 | Package - Ignition Lk Cyl | 1991 - 1994
21171151 | Package - Ignition Lk Cyl | 1995 - 1997 First Design Key
21171147 | Tumbler - Ign Lk Cyl #1 | 1991- 1997 First Design Key
21171148 | Tumbler - Ign Lk Cyl #2 | 1991- 1997 First Design Key
21171149 | Tumbler - Ign Lk Cyl #3 | 1991- 1997 First Design Key
21171150 | Tumbler - Ign Lk Cyl #4 | 1991- 1997 First Design Key
21171160 | Spring - Ign Lk Cyl Tumbler | 1991- 1997 First Design Key
21171145 | Pin - Ign Lk Cyl | 1991- 1997 First Design Key
21171144 | Spring - Ign Lk Cyl Pin | 1991- 1997 First Design Key
21171146 | Bezel - Ign & Start Sw | 1991- 1997 First Design Key

### Claim Information

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Time Guide and Labor Operation Code E7200.