Ignition Switch: Service and Repair

IGNITION AND START SWITCH REPLACEMENT

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Remove the radio. Service and Repair
3. Remove the HVAC control head. Service and Repair
4. Remove the instrument panel (IP) cluster. Instrument Panel Cluster (IPC) - Replacement
5. Remove the ignition switch bezel from the ignition switch, using a small flat-bladed tool.
6. Remove the bolts from ignition switch.
7. Reposition the ignition switch for ease of removal.
8. Insert the key and turn the ignition switch lock cylinder to the "ACC" position.





IMPORTANT: Ignition switch lock cylinder may not rotate or is seized.

9. If the ignition switch lock cylinder is seized or won't rotate, perform the following procedures:
9.1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.
9.2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing and center punch a location on the rib (1) approximately 3/8 inch reward (toward the key entry end) from the cylinder release button.
9.3. Carefully drill a pilot hole through the plastic housing with a 1/8-inch drill bit.
9.4. Carefully drill a larger hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring using a 9/32-inch drill bit.
9.5. Remove portions of the broken spring from the hole using a small suitable tool.
9.6. Grasp the ignition switch lock cylinder and remove it from the switch housing.
9.7. Remove any plastic flashing from the drilling operation, and using compressed air blow out the ignition switch assembly.
9.8. Follow service manual procedures when cylinder coding is required.





10. Depress the transaxle park/lock cable retainer to release, then pull to remove the park/lock cable from the ignition switch.
11. Remove the lock cylinder from the ignition switch, by depressing the retaining tab and pulling the cylinder out with the key.

IMPORTANT: The pass lock electrical connector can not be removed until the ignition switch lock cylinder is removed.

12. Disconnect the pass lock electrical connector from the ignition switch.
13. Disconnect the electrical connectors from the ignition switch.
14. Remove the ignition switch through the IP cluster opening.
15. Remove the bolts from the ignition switch to the bracket.
16. Remove the bracket from the ignition switch.

INSTALLATION PROCEDURE





1. Install the ignition switch bracket to the ignition switch.

NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts to the ignition switch bracket.

TIGHTEN
Bolts to 6 Nm (53 lb in).

3. Install the ignition switch into position through the IP cluster opening.
4. Connect the electrical connectors to the ignition switch.
5. Connect the pass lock electrical connector from the ignition switch.
6. Connect the park/lock cable to the ignition switch.
7. Install the bolts to the ignition switch.

TIGHTEN
Ignition switch bolts to 6 Nm (53 lb in).

8. Insert the key and turn the ignition switch lock cylinder to the "ACC" position.
9. Align and press ignition switch lock cylinder into place.

IMPORTANT: Ignition switch lock cylinder may previously have not rotated or was seized.

10. If the ignition switch lock cylinder previously removed was seized or would not rotate, perform the following procedures:
10.1. Install the new ignition switch lock cylinder as required by rotating both the cylinder and the ignition switch to the "ON" position.
10.2. Push the ignition switch lock cylinder into the ignition switch housing until fully seated.
10.3. It may be necessary to slightly depress the release button as it passes by the 9/32-inch hole previously drilled in the ignition switch housing.

11. Remove the key from the ignition switch.
12. Install the IP cluster.
13. Install the HVAC control head.
14. Install the radio.
15. Connect the negative battery cable.