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Assembling and Coding the Ignition Lock Cylinder

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: If the key code cannot be obtained no identification code is available, proceed to step 1. If the key code is known or a new key code will be used, proceed to step 6.
    IMPORTANT: Be careful to observe and record each tumbler and it's relative position in the lock cylinder as the tumblers are removed.
  1. Remove all of the tumblers by rotating the lock cylinder so that the tumbler slots are facing down.
  2. Hold the lock cylinder close to a flat surface.
  3. Pull the lock cylinder side bar out with your fingers. It may be necessary to tap the lock cylinder on a hard surface to remove all of the tumblers.
    4. Fig 1: Identifying Key Cut Positions & Depths
    GM793164Courtesy of GENERAL MOTORS CORP.
  4. Determine the tumbler numbers and their respective positions. To determine the current key code perform the following steps:
    1. Starting with position (1) the open end of the lock cylinder, find and record the lowest level (tumbler number) that is visible.
    2. Repeat the previous step for positions (2) through 10.
    5. Fig 2: Assembling Tumblers In Slots
    GM621830Courtesy of GENERAL MOTORS CORP.
  5. Starting with position (1), insert the tumblers (2) into their corresponding slots in the coded order.
  6. Using your fingers, pull out the side bar (8) until the tumblers fall completely into the lock cylinder.
  7. Insert one tumbler spring (3) above each tumbler (2).
  8. Lubricate the tumblers using GM P/N 12346241 or equivalent.
  9. Insert the spring retainer (4) into the lock cylinder.
    10. Fig 3: Inserting Lock Retainer
    GM65499Courtesy of GENERAL MOTORS CORP.
  10. Use a flat bladed tool to firmly press the retainer (1) down until the lock cylinder is fully seated in the lock cylinder.
    11. Fig 4: Inspecting Tumbler
    GM65501Courtesy of GENERAL MOTORS CORP.
  11. Inspect for proper tumbler installation:
    1. Hold the spring retainer (2) in position.
    2. Insert the key (1) into the lock cylinder. The side bar (3) should drop down to the level of the lock cylinder. If the side bar does NOT drop down to the level of the lock cylinder, proceed to the previous step 2.
  12. Remove the key from the lock cylinder.
    13. Fig 5: Securing Lock Cylinder Into J 41340
    GM65502Courtesy of GENERAL MOTORS CORP.
  13. Secure the lock cylinder in the J 41340 .
    1. Inspect that the spring retainer is facing up and positioned directly under the punch slots.
    2. Insert the lock cylinder completely into the J 41340 until the lock cylinder bezel contacts the J 41340 .
    3. Tighten the J 41340 holding screw.
    14. Fig 6: Staking Spring Retainer
    GM65503Courtesy of GENERAL MOTORS CORP.
  14. Stake the bezel end of the spring retainer:
    1. Hold the flat side of the punch squarely against the face of the lock cylinder bezel.
    2. Stake the lock cylinder metal over the spring retainer prong.
    15. Fig 7: Staking Opposite Spring Retainer
    GM65504Courtesy of GENERAL MOTORS CORP.
  15. Stake the opposite end of the spring retainer:
    1. Remove the J 41340 punch.
    2. Rotate the J 41340 punch 180 degrees.
    3. Hold the J 41340 punch squarely against the end of the punch slot.
    4. Stake the lock cylinder metal over the spring retainer prong.
  16. Loosen the J 41340 holding screw.
  17. Remove the lock cylinder from the J 41340 .
  18. Inspect that the spring retainer is properly staked. Repeat staking as needed.
  19. Lubricate the lock cylinder retainer slot and the lock cylinder retainer with GM P/N 12345996 or equivalent.
  20. Orient the lock cylinder retainer to the tapered notch in the lock cylinder housing.
  21. Insert the ignition lock cylinder into the ignition lock cylinder housing.
  22. Inspect for proper ignition lock cylinder rotation using the key.
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