Removal and Replacement

DOOR LOCK CYLINDER DISASSEMBLY AND ASSEMBLY









ASSEMBLY SERVICE POINTS

]]A[[ TUMBLER ASSEMBLY





[How to select the tumbler when the tumbler layout information can be obtained by the key code]
1. Note the location and orientation of the lever and rod clip on the lock removed from the vehicle.

2. From the key code select the proper tumbler combinations required to make a functional lock, reference key biting and tumbler placement chart (refer to table 1).

3. Tumblers load from both sides of the cylinder.

4. Locate the tumbler chamber that is closest to the head of the cylinder plug. That is tumbler ward number 1 and the first number of the key code. Tumbler ward number 3, 5 and 7 are also located on that side of the cylinder plug (odd on one side even on other).

5. Place one tumbler spring in each of the four spring pockets.

6. Using the appropriate tumbler number (tumbler number is stamped on tumbler and matches cut depth) place a tumbler in each chamber and depress tumbler tilting slightly towards the spring. The tumbler should drop freely in place and be retained. After all tumblers are inserted into the cylinder plug insert the key to make sure the tumblers drop flush with the cylinder plug body. If one does not remove and replace with thew correct tumbler that matches the cut of the key.

7. Turn the cylinder plug over and repeat the same process for chambers 2, 4, 6, and 8. Insert the key and make sure all the tumblers drop flush with the diameter of the cylinder.

Table 1: Key code to tumbler placement







NOTE:
The mark X in the table indicates the stamped number (from 1 to 4) on the tumbler.













[How to select the tumbler when the tumbler layout information cannot be obtained by the key code]
8. The repair kit contains 20 tumblers (five tumblers for each No. 1 to 4.)

9. Insert the tumbler spring into the cylinder plug spring pocket.

10. Set the tumbler No. 1 onto the cylinder plug tumbler chamber, and insert the key.
Then, check that the tumbler is not protruding from the cylinder plug.

11. When the tumbler is not protruding, the correct tumbler is selected. Otherwise, the wrong tumbler is selected.If the wrong tumbler has been selected, remove the tumbler No. 1, and set the tumbler in the order from No. 2 to 4. Then, check the key insertion state and select the tumbler which does not protrude from the cylinder plug.

12. Repeat the steps previously mentioned, and set the correct tumbler into all tumbler chambers. Insert the key at last, and check that all the tumblers are clearly arranged, not protruding from the cylinder plug.

]]B[[ CYLINDER SUB-ASSEMBLY ASSEMBLY





Apply the supplied grease to body surfaces of the cylinder opposite of the tumblers, in the keyway of the cylinder plug head and actuator pocket, and the inside diameter of the case.

]]C[[ CAP ASSEMBLY

1. Assemble the cap onto the cylinder plug.





2. Bend the four claws on the cap using the flat-tipped screw driver.