Service Procedures For New Lock System (96-T-67)

Publication date: 1996-12-01
Reference number: 96-T-67

SERVICE PROCEDURES FOR NEW LOCK SYSTEM

TECHNICAL SERVICE BULLETIN

Reference Number(s): 96-T-67, Date of Issue: December, 1996

SERVICE MANUAL PROCEDURES FOR NEW LOCK SYSTEM FOR INTERIM 1997 SATURNS

APPLICATION

Model(s): 1997 Saturn

Group: General Information - 05

Corporation No.: 680106

Bulletin No.: 96-T-67

Date: December, 1996

PURPOSE

Saturn interim 1997 vehicles will be manufactured with a new lock system for the ignition, door and rear compartment/liftgate locks. (This new lock system will be referred to as second design and the previous lock system will be identified as first design.) To help identify if a 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. See Fig 1 .

Refer to this bulletin for new general information and coding procedures for the new second design lock system.

KEY IDENTIFICATION AND USAGE

The second design lock system is a one key system with a key profile that has a two-sided cut, and milled grooves that are unique to the Saturn lock system. The number of tumblers in the ignition cylinder has increased from seven to nine. See Fig 2 .

CUTTING KEYS

The Saturn approved key cutting tool requires adapter kit SA9703B to cut the second design keys. The adapter kit consists of a depth knob, spacing plate, key insert, and punch and die assembly. To install adapter kit to key cutting tool, follow steps in instruction manual provided with key cutting tool. The spacing plate provided with the adapter kit accommodates positions 1 through 10. The Saturn key uses positions 2 through 10.

NOTE: First design keys CANNOT be cut with the adapter kit.

The customer information card or the retailer records will show the key code as a four-digit numeric code. To determine the actual cut sequence of the key from this code, look up the code in the "1991-97 Saturn Key Code Manual" and the cut sequence will be shown to the right of the code listing. The master cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key to work properly in all the locks on the vehicle.

DETERMINING THE KEY CODE

Insert the key in the Saturn approved key cutting tool with the tip of the key against the stop.
With the cutting die in the down position, move the carriage toward the die until it bottoms out, and record the depth (1, 2, 3 or 4).
Repeat for each cut position, 2 through 10. Positions are read from key head to key tip.

PROCEDURES

LOCK CYLINDER CODING

NOTE: When the tumblers are removed from the lock cylinder, tumbler springs may fall out. See Fig 3 .

Push tumblers out of lock cylinder using a thin-bladed screwdriver.
For door and rear compartment or liftgate locks, if necessary, remove side-bar assembly by pushing it inward while tapping the cylinder, causing it to fall out.
Select the correct tumblers for the desired code by the number stamped on the tumbler. Fig 4 shows a 4 tumbler.
1. Door, rear compartment and liftgate lock cylinders reads key cut positions 5 through 10.
2. Ignition lock cylinder reads key cut positions 2 through 10.
  NOTE: Make sure side-bar (if used) and tumbler springs are in place before installing tumblers. See Fig 5 .
Install tumblers by applying downward pressure until they lock into position.
To check coding of the cylinder, insert key. If coding is correct,tumblers and side-bar will be flush with cylinder with key inserted.
For assembly, oil lock set with a light oil or graphite lubricant.

DOOR LOCK CYLINDER

Removal

Remove cap from lock cylinder using a thin-bladed screwdriver to carefully pry cap from cylinder.
NOTE: When shutter is removed, the shutter springs may fall out.
Remove shutter and shutter springs. See Fig 6 .
Insert key into cylinder, turn it a quarter turn clockwise, and remove cylinder from housing. See Fig 7 .
If necessary, remove pawl from slot in housing.
To code lock cylinder(s), refer to LOCK CYLINDER CODING .

Installation

With key inserted into cylinder, install cylinder into case. See Fig 11 .
Rotate cylinder and install spring and locking pin.
Install lock cylinder bezel to lock cylinder housing. See Fig 10 .
NOTE: Actuator blade within ignition module housing must be in the ACC position to install lock cylinder assembly. If rotated, (replace it to the ACC position using needle nose pliers. See Fig 12 .
With lock cylinder in ACC position, slide lock cylinder assembly into ignition module. See Fig 9 .
Install steering column upper shroud, panel and shroud fasteners. See Fig 8 . TORQUE: 3 N.m (26 in-lb).

REAR COMPARTMENT AND LIFTGATE LOCK CYLINDER

Removal

Remove E-clip at rear of lock cylinder and remove pawl. See Fig 13 .
Unhook return spring from case and slide spring from cylinder.
Remove cap from lock cylinder by inserting thin-bladed screwdriver between cap and case, and carefully prying cap a from case. See Fig 14 .
NOTE: When shutter is removed, the shutter springs may fall out.
Remove shutter.
Insert key and rotate a quarter-turn clockwise, and slide cylinder from housing. See Fig 15 .
To code lock cylinder, refer to LOCK CYLINDER CODING .

Installation

With key inserted into cylinder, install cylinder into housing.
Install shutter spring and shutter assembly. See Fig 14 .
Install cap to lock cylinder housing.
Slide spring on to cylinder and hook to case.
Install pawl to lock cylinder and secure with E-clip. See Fig 13 .

Fig 1: First & Second Key Designs - Identification

Fig 2: First & Second Key Designs - 7 & 10 Positions

Fig 3: Lock Cylinder Tumblers - Identification

Fig 4: Tumbler - Code Number Location

Fig 5: Side-Bar & Tumbler Springs - Identification

Fig 6: Shutter & Shutter Springs - Location

Fig 7: Cylinder & Key - Location

Fig 8: Steering Column Upper Shroud Panel & Shroud Fasteners, I.D.

Fig 9: Ignition Module Assembly Locking Button - Location

Fig 10: Lock Cylinder Bezel - Location

Fig 11: Cylinder, Key & Case - Identification

Fig 12: Actuator Blade & Ignition Module Housing - Location

Fig 13: Lock Cylinder E-Clip & Pawl - Location

Fig 14: Lock Cylinder Cap & Case - Location

Fig 15: Cylinder, Key & Housing - Location

PARTS INFORMATION

Part Number	Description	Usage
21170409	Package - Frt S/D Lk Cyl	ALL
21170390	Pagage - R/Compt Lid Lk Cyl	A69/27
21170414	Package -Ign Lk Cyl	ALL
21170408	Package - L/Gate Lk Cyl	A35
21170632	Package - Frt S/D Lk Cyl	RHD
21170338	Lock Service Kit Complete	ALL

LOCK SERVICE KIT

Part Number	Description	Usage
21170389	Box - Lk Service Kit	N/A
21170413	Pawl - Frt S/D Lk Cyl, L	ALL
21170412	Pawl - Frt S/D Lk cyl, R	ALL
21170406	Pawl - R/cmpt Lid Lk Cyl	A69/27
21170407	Pawl - L/Gate Lk Cyl	A35
21170411	Spring - Ign Lk Pin	ALL
21170415	Pin - Ign Lk Cyl	ALL
21095084	Switch Asm - Frt S/D Lck	RHD
21044505	Bezel - Ign & Start Sw	ALL
21170392	Tumbler - Lk Cyl #1	ALL
21170393	Tumbler - Lk Cyl #2	ALL
21170394	Tumbler - Lk Cyl #3	ALL
21170395	Tumbler - Lk Cyl #4	ALL
21170396	Shutter - Dr & R/Compt Lk Cyl Cap	ALL
21170397	Spring - Dr & R/Compt Lk Cyl Shtr	ALL
21170398	Spring - Dr, R/Cmpt & Ign Lk Cyl Tumb	ALL
21170339	Clip - R/Compt Lid Lk Cyl	ALL
21170400	Retainer - R/Cmpt Lid Lk Cyl	A69/27
21170401	Gasket - R/Cmpt Lid Lk Cyl	A69/27
21170402	Gasket - L/Gate Lk Cyl	A35
21170403	Spring R/Cmpt Lid Lk	A69/27
21170577	Spring L/Gate Lk Cyl Ret	A35
21170404	Cap - Frt S/D Lock Cyl	ALL
21077412	Cap - L/Gate Lk Cyl	A35
21097822	Boot - R/Cmpt Lid Lk Cyl	A69/27
21170452	Side Bar - Dr Lk Cyl	ALL
21170453	Spring - Side Bar	ALL
21170391	Key - Dr & R/Compt & Ign	ALL