MIL ON - Intermittent Loss of Power To Accessories
BULLETIN NO.: 96-T-50AISSUE DATE: June, 1997
GROUP/SEQ. NO.: Electrical-02
CORPORATION NO.: 688103R
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)
Due to changes under MODELS AFFECTED to distinguish 1997 vehicles with first design locks, this bulletin supercedes 96-T-50, which should be discarded.
MODELS AFFECTED:
1995-1996 Saturns, and 1997 Saturns equipped with first design locks
CONDITION:
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.
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.
IMPORTANT:
To help identify if a 1997 vehicle is equipped with a first or second design lock system, check the key. The new second design lock system has a different shaped key than the key used in the first design lock system (refer to the above illustrations).
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, (1) 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 corner 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