Ignition Switch: Service and Repair

Ignition Switch Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 and SIR Disabling and Enabling Zone 5 in Restraint Systems
3. Remove the accessory trim plate from the I/P carrier.
4. Remove the instrument panel cluster from the I/P carrier.




5. Remove the ignition switch bolts from the ignition switch.
6. Insert the key into the ignition switch lock cylinder. Rotate the key to the ON position.




7. If the ignition switch lock cylinder is seized or won't rotate, perform the following procedure:

1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.
2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing.
On the key entry side of the switch housing center punch a location on the rib (1) approximately 3/8 of an inch from the cylinder release button (2).
3. Carefully drill a pilot hole through the plastic housing with a 1/8 inch drill bit.
4. Using a 9/32 inch drill bit carefully drill a hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring.
5. Remove portions of the broken spring from the hole using a small suitable tool.
6. Grasp the ignition switch lock cylinder and remove the cylinder from the switch housing.
7. Remove any plastic flashing from the drilling operation, and using compressed air blow out the ignition switch assembly.




8. Disconnect the electrical connectors from the ignition switch.
9. Release the transaxle park/lock cable retainer, then pull outward to remove the cable from the ignition switch.




10. Press the ignition switch lock cylinder release plunger. The release plunger is located at the four o'clock position on the ignition switch housing.
11. Use the key in order to pull the ignition switch lock cylinder from the ignition switch housing.




12. Disconnect the pass key electrical connector from the ignition switch housing.
13. Remove the ignition switch housing through the opening in the I/P cluster.

Installation Procedure




1. Position the ignition switch housing through the opening in the I/P cluster.
2. Connect the pass key electrical connector to the ignition switch housing.
3. If you are replacing the ignition lock cylinder, you must code the new cylinder. Refer to Key and Lock Cylinder Coding.




4. Use the key in order to install the ignition switch lock cylinder to the switch housing.
5. If the ignition switch lock cylinder previously removed was seized or would not rotate, perform the following procedure:

1. Install the new ignition switch lock cylinder as required by rotating both the cylinder and the ignition switch to the ON position.
2. Push the ignition switch lock cylinder into the ignition switch housing until fully seated.
3. It may be necessary to slightly depress the release button, as the button passes by the 9/32-inch hole previously drilled in the ignition switch housing.




6. Connect the park lock cable to the ignition switch housing.
7. Connect the electrical connectors to the ignition switch.




8. Install the ignition switch housing to the I/P carrier.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the ignition switch bolts.

Tighten the bolts to 10 N.m (88 lb in).

10. Install the instrument panel cluster to the I/P carrier.
11. Install the accessory trim plate to the I/P carrier.
12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 and SIR Disabling and Enabling Zone 5 in Restraint Systems.
13. Connect the negative battery cable.
14. Perform the Passlock(TM) learn procedure. Refer to Theft Systems Description and Operation in Theft Deterrent.