GM Corsica/Beretta 1988-1996 Repair Guide

Ignition Lock Cylinder

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REMOVAL & INSTALLATION



The manufacturer recommends that the steering column be removed from the vehicle prior to ignition lock removal and installation.

1988-90 Vehicles

See Figure 1

STANDARD STEERING COLUMN
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left-side lower trim panel.
  4.  
  5. Remove the steering column-to-support screws and lower the steering column.
  6.  

Vehicles equipped with floor shift and automatic transaxles use an ignition switch inhibitor and park lock cable. On these models the park lock cable must be disconnected from the ignition switch inhibitor, by releasing the locking tab, before removing the column.

  1. Detach the dimmer switch and turn signal switch connectors.
  2.  
  3. Remove the wiring harness-to-firewall nuts and steering column.
  4.  
  5. Remove the steering column-to-steering gear bolt and the steering column from the vehicle.
  6.  
  7. Remove the combination switch, as outlined in this section.
  8.  
  9. Place the lock cylinder in the RUN position.
  10.  
  11. Remove the steering shaft assembly and turn signal switch housing as an assembly.
  12.  
  13. Using the Terminal Remover tool No. J-35689-A or equivalent, disconnect and label the wires "F" and "G" on the connector at the buzzer switch assembly from the turn signal switch electrical harness connector.
  14.  
  15. Place the lock cylinder in the RUN position and remove the buzzer switch.
  16.  
  17. Place the lock cylinder in the ACCESSORY position. Remove the lock cylinder retaining screw and the lock cylinder.
  18.  
  19. Remove the dimmer switch nut/bolt, the dimmer switch and actuator rod.
  20.  
  21. Remove the dimmer switch mounting stud (the mounting nut was mounted to it).
  22.  
  23. Remove the ignition switch-to-steering column screws and the ignition switch.
  24.  
  25. Remove the lock bolt screws and the lock bolt.
  26.  
  27. Remove the switch actuator rack and ignition switch.
  28.  
  29. Remove the steering shaft lock and spring.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the ignition lock cylinder - 1988-90 vehicles

To install:
  1. Observe the following tightening specifications when installing. Tighten the steering lock screw to 27 inch lbs. (3 Nm), the dimmer switch stud to 35 inch lbs. (4 Nm), the turn signal switch housing screws to 88 inch lbs. (10 Nm), the turn signal switch screws to 35 inch lbs. (4 Nm) and the steering wheel lock nut to 30 ft. lbs. (41 Nm).
  2.  
  3. To install the lock bolt, lubricate it with lithium grease and install the lock bolt, spring and retaining plate.
  4.  
  5. Lubricate the teeth on the switch actuator rack. Install the rack and the ignition switch through the opening in the steering bolt until it rests on the retaining plate.
  6.  
  7. Install the steering column lock cylinder set by holding the barrel of the lock cylinder, insert the key and turn it to the ACCESSORY position.
  8.  
  9. Install the lock set in the steering column while holding the rack against the lock plate.
  10.  
  11. Install the lock retaining screw. Insert the key in the lock cylinder and turn the lock cylinder to the START position and the rack will extend.
  12.  
  13. Center the slotted holes on the ignition switch mounting plate and install the ignition switch mounting screw and nut.
  14.  
  15. Install the dimmer switch and actuator rod into the center slot on the switch mounting plate.
  16.  
  17. Install the buzzer switch and turn the lock cylinder to the RUN position. Push the switch in until it is bottomed out with the plastic tab that covers the lock retaining screw.
  18.  
  19. Install the steering shaft and turn signal housing as an assembly.
  20.  
  21. Install the turn signal switch.
  22.  
  23. The remainder of installation is the reverse of the removal procedures.
  24.  

TILT STEERING COLUMN
  1. Disconnect the negative battery cable.
  2.  
  3. Tilt the column up as far as it will go and remove the left-side lower trim panel.
  4.  
  5. Remove the steering column-to-support screws and lower the steering column.
  6.  

Vehicles equipped with floor shift and automatic transaxles use an ignition switch inhibitor and park lock cable. On these models the park lock cable must be disconnected from the ignition switch inhibitor, by releasing the locking tab, before removing the column.

  1. Disconnect the dimmer switch and turn signal switch connectors.
  2.  
  3. Remove the wiring harness-to-firewall nuts and steering column.
  4.  
  5. Remove the steering column-to-steering gear bolt and the steering column from the vehicle.
  6.  
  7. Remove the combination switch.
  8.  
  9. Using a flat-type pry blade, position it in the square opening of the spring retainer, push downward (to the left) to release the spring retainer. Remove the wheel tilt spring.
  10.  
  11. Remove the spring retainer, the tilt spring and the tilt spring guide.
  12.  
  13. Remove the shoe pin retaining cap. Using the Pivot Pin Removal tool No. J-21854-01 or equivalent, remove the 2 pivot pins.
  14.  
  15. Place the lock cylinder in the RUN position.
  16.  
  17. Pull the shoe release lever and release the steering column housing.
  18.  
  19. Remove the column housing, the steering shaft assembly and turn signal switch housing as an assembly.
  20.  
  21. Using the Terminal Remover tool No. J-35689-A or equivalent, tag and detach the wires "F" and "G" on the connector at the buzzer switch assembly from the turn signal switch electrical harness connector.
  22.  
  23. Place the lock cylinder in the RUN position and remove the buzzer switch.
  24.  
  25. Place the lock cylinder in the ACCESSORY position. Remove the lock cylinder retaining screw and the lock cylinder.
  26.  
  27. Remove the dimmer switch nut/bolt, the dimmer switch and actuator rod.
  28.  
  29. Remove the dimmer switch mounting stud (the mounting nut was attached to it).
  30.  
  31. Remove the ignition switch-to-steering column screws and the ignition switch.
  32.  
  33. Remove the lock bolt screws and the lock bolt.
  34.  
  35. Remove the switch actuator rack and ignition switch.
  36.  
  37. Remove the steering shaft lock and spring.
  38.  

To install:
  1. Observe the following tightening specifications when installing. Tighten the steering lock screw to 27 inch lbs., the dimmer switch stud to 35 inch lbs., the turn signal switch housing screws to 88 inch lbs., the turn signal switch screws to 35 inch lbs. and the steering wheel lock nut to 30 ft. lbs.
  2.  
  3. To install the lock bolt, lubricate it with lithium grease and install the lock bolt, spring and retaining plate.
  4.  
  5. Lubricate the teeth on the switch actuator rack. Install the rack and the ignition switch through the opening in the steering bolt until it rests on the retaining plate.
  6.  
  7. Install the steering column lock cylinder set by holding the barrel of the lock cylinder, insert the key and turn the key to the ACCESSORY position.
  8.  
  9. Install the lock set in the steering column while holding the rack against the lock plate.
  10.  
  11. Install the lock retaining screw. Insert the key in the lock cylinder. Turn the lock cylinder to the START position and the rack will extend.
  12.  
  13. Center the slotted holes on the ignition switch mounting plate. Install the ignition switch mounting screw and nut.
  14.  
  15. Install the dimmer switch and actuator rod into the center slot on the switch mounting plate.
  16.  
  17. Install the buzzer switch and turn the lock cylinder to the RUN position. Push the switch in until it is bottomed out with the plastic tab that covers the lock retaining screw.
  18.  
  19. Install the steering shaft and turn signal housing as an assembly.
  20.  
  21. Install the turn signal switch. To complete the installation, reverse the removal procedures.
  22.  

1991-92 Vehicles

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Disable the SIR system as outlined in Chassis Electrical .
  4.  
  5. Remove the steering wheel.
  6.  
  7. Remove the coil assembly retaining ring.
  8.  
  9. Lift the coil assembly from the end of the steering shaft and allow coil to hang freely.
  10.  
  11. Remove the wave washer.
  12.  
  13. If equipped with a standard column, remove the spacer shaft lock.
  14.  
  15. Remove the shaft lock retaining ring using tool J-23653-C or equivalent, to compress the shaft lock.
  16.  
  17. Pry off the retaining ring.
  18.  
  19. Remove the shaft lock.
  20.  
  21. Remove the turn signal cancelling cam assembly.
  22.  
  23. Remove the upper bearing spring.
  24.  
  25. Position the turn signal lever to the right turn position.
  26.  
  27. Remove the multi-function lever by performing the following:
    1. Ensure the lever is in the center or OFF position.
    2.  
    3. If equipped with cruise control, disconnect the cruise control connector from the steering column assembly.
    4.  
    5. Pull the lever straight out of the turn signal switch.
    6.  

  28.  
  29. Remove the hazard knob assembly.
  30.  
  31. Remove the screw and signal switch arm. If equipped with tilt column and cruise control, allow the switch arm to hang freely.
  32.  
  33. Remove the turn signal switch screws. Allow the switch to hang freely.
  34.  
  35. Disconnect the turn signal/hazard switch assembly terminal from the instrument panel harness.
  36.  
  37. If equipped with tilt column, disconnect the buzzer switch assembly terminals from the turn signal/hazard assembly connector. Remove the tan/black wire lead from cavity E and the light green wire from the cavity F.
  38.  
  39. Remove the upper steering column bolts.
  40.  
  41. Remove the wiring protector.
  42.  
  43. Connect a length of wire to the turn signal/hazard assembly terminal connector to aid in reassembly.
  44.  
  45. Gently pull the wire harness through the steering column housing shroud, steering column housing and lock assembly cover.
  46.  
  47. Detach the wire from the connector.
  48.  
  49. Ensure the lock cylinder is in the LOCK position. Remove the lock cylinder attaching screw.
  50.  
  51. Remove the lock cylinder from the column.
  52.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the ignition lock cylinder mounting - 1991-96 vehicles

To install:
  1. Install the lock cylinder and attaching screw. Tighten to 40 inch lbs. (4.5 Nm).
  2.  
  3. Turn the ignition key to the RUN position.
  4.  
  5. Install the buzzer switch.
  6.  
  7. Connect the wire to the turn signal/hazard switch assembly connector.
  8.  
  9. Gently pull the connector through the steering column housing shroud, steering column housing and lock assembly cover.
  10.  
  11. Remove the wire.
  12.  
  13. Install the wiring protector.
  14.  
  15. If disconnected, connect the buzzer switch terminals to the turn signal/hazard switch assembly connector. Insert the tan/black wire lead into cavity E and the light green wire into cavity F.
  16.  
  17. Connect the turn signal/hazard switch assembly connector to the instrument panel harness.
  18.  
  19. Install the steering column support bracket bolts to the steering column. Tighten to 22 ft. lbs. (30 Nm).
  20.  
  21. Install the steering column upper support bolts. Tighten to 20 ft. lbs. (28 Nm).
  22.  
  23. Install the turn signal switch assembly and attaching screws. Tighten to 20 inch lbs. (2 Nm).
  24.  
  25. Install the hazard knob assembly.
  26.  
  27. Install the multi-function lever by performing the following:
    1. Align the tab on the turn signal switch with the notch in the pivot of the turn signal switch.
    2.  
    3. Push the lever into the turn signal switch.
    4.  
    5. If equipped with cruise control, connect the connector to the steering column assembly.
    6.  

  28.  
  29. Install the turn signal cancelling cam assembly. Lubricate with a synthetic grease.
  30.  
  31. Install the shaft lock.
  32.  
  33. Install the shaft lock retaining ring, lining up to block tooth on the shaft. Use tool J-23653-C to compress the shaft lock.
  34.  
  35. If equipped with a standard column, install the spacer shaft lock.
  36.  
  37. Install the wave washer.
  38.  
  39. Ensure the coil assembly is centered.
  40.  

The coil assembly will become uncentered if the steering column is separated from the steering gear and is allowed to rotate or the centering spring is pushed down, letting the hub rotate while the coil is removed from the steering column.

  1. Install the coil assembly using the horn tower on the cancelling cam assembly inner ring and projections on the outer ring for alignment.
  2.  
  3. Install the coil assembly retaining ring. The ring must be firmly seated in the groove on the shaft. Gently pull the lower coil assembly wire to remove any wire kinks that may be inside the column.
  4.  
  5. Install the steering wheel.
  6.  
  7. Enable the SIR system as outlined earlier in this section.
  8.  
  9. Connect the negative battery cable.
  10.  

 
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