Assembling and Coding Ignition Lock Cylinder

The ignition lock cylinder uses 8 of the 10 cut positions, 1-8. The tumbler orientations alternate in adjacent locations from side to side, with 4 tumblers on each side.

Fig 1: Ignition Lock Cylinder
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: The ignition lock cylinder tumblers (3) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder.
1. Hold the uncoded cylinder assembly (1) so that the side with the retention lug is facing upward.
2. Insert 1 tumbler spring (2) into each of the tumbler spring holes.
3. The first tumbler to be loaded will be the key cut position #1, the first number in the key code. Determine the cut depth at this position and insert the corresponding tumbler (3) in the slot nearest the front of the cylinder assembly (1). This is the side where the key would be inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the three remaining tumblers (3) into the tumbler slots at key cut positions 3, 5, and 7.
5. Verify the correct loading of the tumblers (3) by holding the tumblers in position and inserting the matching key into the cylinder assembly (1). The tumblers should be flush with the outside diameter of the cylinder assembly.
IMPORTANT: The tumblers (3) are NOT self-retaining and must be held in place.
6. Rotate the cylinder assembly (1) so that the side with the retaining pin (4) hole is facing upward. Remove the matching key.
7. Insert a tumbler spring (2) into each of the 4 tumbler spring holes.
8. The first tumbler to be loaded is key cut position #2. Determine the cut depth at this position and insert the corresponding tumbler (3) in the slot nearest the front of the cylinder assembly (1).
9. In the same manner, determine the cut depth and corresponding tumbler and install the three remaining tumblers (3) into the tumbler slots at key cut positions 4, 6, and 8.
10. Verify the correct loading of the tumblers (3) by holding the tumblers in position and inserting the matching key into the cylinder assembly (1). The tumblers should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces using the provided lubrication.
12. With the matching key fully inserted into the coded cylinder assembly, rotate the cylinder so that the side with the retaining pin (4) hole is facing upward.
IMPORTANT: The retaining pin spring and retaining pin are not self-retaining and must be held in place until the coded cylinder is installed into the case assembly (6).
13. Insert one retaining pin spring (5) and one retaining pin (4) into the hole located behind the 4 tumblers.
CAUTION: Wear safety glasses in order to avoid eye damage.
14. With the matching key fully inserted into the coded cylinder assembly and the retaining pin (4) fully depressed into the cylinder, align the retaining lug on the cylinder with the groove, which extends the full length of the inside diameter of the case assembly.
15. Install the coded cylinder assembly into the case assembly (6). Hold the retaining pin spring (5) and the retaining pin (4) in the cylinder until the retaining pin spring and the retaining pin enter the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retaining pin snaps into place, limiting the rotation of the cylinder assembly.
16. Remove the matching key and install the theft deterrent module (7) onto the case assembly (6). Position the retaining clips of the theft deterrent module correctly on the case assembly.
17. Install the ignition cylinder bezel (8) through the theft deterrent module (7) and onto the case assembly (6). Position the retaining clips of the ignition cylinder bezel correctly on the case assembly.