GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Ignition Switch

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REMOVAL & INSTALLATION



1982-91 Vehicles

See Figures 1, 2 and 3

The switch is located on the steering column and is completely inaccessible without first lowering the steering column. The switch is actuated by a rod and rack assembly. A gear on the end of the lock cylinder engages the toothed upper end of the rod.

  1. Lower the steering column; be sure to properly support it.
  2.  
  3. Put the switch in the OFF-UNLOCKED position. With the cylinder removed, the rod is in OFF-UNLOCKED position when it is in the next to the uppermost detent.
  4.  
  5. Unfasten the two switch screws and remove the switch assembly.
  6.  



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Fig. Fig. 1: Removal and installation of the ignition switch and related steering column components - 1990 vehicle shown



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Fig. Fig. 2: Exploded view of a steering column including the ignition switch - 1990 vehicle with standard column shown



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Fig. Fig. 3: Exploded view of the steering column including the ignition switch - 1990 vehicle with tilt column shown

To install:
  1. Before installing, move the new switch slider (standard columns with automatic transaxle) to the extreme left position. Move the switch slider (standard columns with manual transaxle) to the extreme left position. Move the slider (adjustable columns with automatic transaxle) to the extreme right position and then move the slider one detent to the left (off lock). Move the slider (adjustable columns with manual transaxle) to the extreme right position.
  2.  
  3. Install the activating rod into the switch and assemble the switch on the column. Tighten the mounting screws. Use only the specified screws, since overlength screws could impair the collapsibility of the column.
  4.  
  5. Reinstall the steering column.
  6.  

1992-94 Sunbird

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the pad and horn lead, retainer and nut and remove the steering wheel from the column, using a suitable puller.
  4.  
  5. Remove the tilt lever, if so equipped.
  6.  
  7. Unfasten the 2 lower column cover retaining screws.
  8.  
  9. Remove the 3 bottom retaining screws from lower column cover.
  10.  
  11. Unfasten the washer head screw and hex nut.
  12.  
  13. Remove the dimmer switch assembly from the rod. Remove the dimmer switch and ignition switch mounting stud.
  14.  
  15. Disconnect the ignition switch from the actuator assembly, by unfastening the two cross recess screws. Detach the electrical connector, then remove the switch.
  16.  



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Fig. Fig. 4: Location and mounting of the ignition switch - 1994 Sunbird shown

To install:

Install the ignition switch to the jacket with the switch in the "OFF-LOCK" position. A new swtich will be pinned in the "OFF-LOCK" position. Don't forget to remove the plastic pin after the switch is attached to the column

  1. Connect the ignition switch to the ignition switch actuator assembly and adjust as follows:
    1. Move the switch slider to the extreme left position.
    2.  
    3. Move the switch slider one detent to the right "OFF-LOCK" position.
    4.  

  2.  
  3. Install the ignition switch assembly and stud. Tighten the retaining screws to 30 inch lbs. (3.4 Nm).
  4.  
  5. Fasten the dimmer switch assembly to the rod.
  6.  
  7. Install the hex nut and washer head screw and tighten finger-tight.
  8.  
  9. Adjust the dimer switch as follows:
    1. Place a 3 / 32 in. (2.4mm) drill bit in the hole in the switch to limit travel.
    2.  
    3. Position the switch on the column and push against the dimmer switch rod to remove all lash.
    4.  
    5. Remove the drill bit.
    6.  

  10.  
  11. Attach the switch electrical connector.
  12.  
  13. Install the steering column, as outlined in this section.
  14.  
  15. Connect the negative battery cable.
  16.  

1992-94 Cavalier

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. If equipped, disable the SIR system. For details, please refer to the procedure located in Chassis Electrical of this repair guide.
  4.  
  5. Remove the steering column as outlined later in this section.
  6.  
  7. Disconnect the wire harness from the ignition switch.
  8.  
  9. Unfasten the retaining screws, then remove the switch.
  10.  

To install:


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Fig. Fig. 5: Ignition switch mounting - 1995 vehicle shown

  1. Installation is the reverse of the removal procedure.
  2.  
  3. If equipped, enable the SIR system as outlined in Chassis Electrical of this repair guide.
  4.  

 
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