Volkswagen Cars 2000-05

Ignition Lock Cylinder

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Center the steering wheel.
  4.  
  5. Remove the air bag.
  6.  
  7. Remove the steering column switches.
  8.  
  9. If the vehicle is equipped with an automatic transmission, detach the shift lock cable from the lock cylinder housing.
  10.  
  11. Remove the adapter sleeve from the steering column.
  12.  
  13. Remove the spring and horn contact ring from the steering column assembly.
  14.  
  15. Detach the sheer bolt.
  16.  
  17. Insert the ignition key and unlock the cylinder, then detach the wiring connectors.
  18.  
  19. Once all wiring has been detached, slide the housing off the steering column.
  20.  
  21. Mark and drill the lock cylinder as shown and described in the above procedure.
  22.  
  23. Compress the stop spring and pull the lock cylinder out of the steering column housing.
  24.  
  25. Put the new lock cylinder into the steering lock housing.
  26.  
  27. Insert the key into the lock cylinder.
  28.  
  29. While you gently turn the key, insert the lock cylinder fully into the housing.
  30.  
  31. The rest of the installation procedure is the reverse of removal.
  32.  


NOTE
Always use a new shear pin when installing the lock cylinder.


CAUTION
Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS. Handling of the SRS components requires extreme care. Special tools are also required. If in doubt, see a qualified service technician to ensure proper removal and installation of air bag system components.

  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Remove the SRS air bag, steering wheel and column switch assemblies. For additional information, please refer to the following topic(s): Steering Wheel, Turn Signal/Hi-Low Beam/Wiper Switch Removal and Installation.
  4.  
  5. Turn the ignition switch to the ON position.
  6.  
  7. Insert a length of steel wire about 3 / 64 inch (1.2mm) in diameter into the small opening near to the bottom ignition key slot and press down fully at a slight angle, aiming toward the outer bottom edge of the housing and remove the lock cylinder by pulling on the ignition key.
  8.  
  9. Installation is in reverse order of removal noting the following:
  10.  
  11. The ignition switch must be in the ON position before installing the lock cylinder.
  12.  
  13. Press the lock cylinder with the key installed into the steering lock housing, while pressing with the length of steel wire used during removal, pressing the steel wire down fully at a slight angle, aiming toward the outer bottom edge of the housing and pushing the lock cylinder into the housing.
  14.  

  1. Disarm the SRS system, as outlined in the Chassis Electrical System.
  2.  
  3. Remove the steering wheel, as outlined in this section.
  4.  
  5. Remove trim for steering column switch and slip ring or Steering Angle Sensor if installed.
  6.  
  7. Unfasten the bolt from the steering column switch and remove steering column switch.

    Click image to see an enlarged view

    Fig. Unfasten the bolt from the steering column switch and remove steering column switch

  8.  
  9. Remove plastic cover from over the shear bolts.
  10.  
  11. The ignition key removal lock cable must be disconnected on vehicles with automatic transmission, as follows:
    1. Shift the selector lever into position "P" if necessary.
    2.  
    3. Turn the ignition key (A) to the ON position.
    4.  
    5. Press the wire clip (1) up or down according to installation position and pull at the same ignition lock cable (2) out at the same time.

      Click image to see an enlarged view

      Fig. Removing the ignition key removal lock cable-with automatic transaxle only

    6.  

  12.  
  13. Use a suitable chisel to carefully chisel off the shear head bolts.

    Click image to see an enlarged view

    Fig. Use a suitable chisel to carefully chisel off the shear head bolts

  14.  
  15. Detach the connector from the ignition starter switch.
  16.  
  17. Remove the ignition switch/lock cylinder.
  18.  

To install:

  1. Reconnect connector for ignition starter switch.
  2.  
  3. For vehicles with an automatic transaxle, connect ignition key removal lock cable:
    1. Make sure the shift selector lever is in the "P" position.
    2.  
    3. Turn the ignition key (A) to the ON position.
    4.  
    5. Push the lock cable (2) into steering lock housing until wire clip (1) engages.

      Click image to see an enlarged view

      Fig. Connecting the ignition key removal lock cable-with automatic transaxle only

    6.  

  4.  
  5. Install new shear bolts and tighten them until their heads shear off.
  6.  
  7. If equipped with ESP, install the steering angle sensor
  8.  
  9. Install the trim for steering column switch and the steering column switch
  10.  
  11. Install the steering wheel and air bag unit.
    CAUTION
    Make sure there are no occupants in the vehicle before connecting the battery cable.

  12.  
  13. Connect the negative battery cable, then check for proper SRS operation.
  14.  

  1. Disarm the SRS system, as outlined in the Chassis Electrical System.
  2.  
  3. Remove the steering wheel, as outlined in this section.
  4.  
  5. Remove upper and lower trim from the steering column switch
  6.  
  7. Remove the steering column switch. Refer to the procedure for the Multi-function Switch or Turn Signal (Combination) Switch in this section.
  8.  
  9. For the Passat, carefully detach the harness connector (arrow) for the anti-theft immobilizer reading coil from the lock cylinder.
    NOTE
    The induction coil for anti-theft immobilizer is connected to lock cylinder and cannot be replaced individually.



    Click image to see an enlarged view

    Fig. Carefully detach the harness connector (arrow) for the anti-theft immobilizer reading coil from the lock cylinder

  10.  
  11. Insert ignition key into lock cylinder and turn the key to the "Drive" position. Refer to the illustration for lock cylinder positions.
  12.  
  13. Insert a piece of steel wire (about 1.2 mm in diameter) into the hole next to ignition key (arrow).

    Click image to see an enlarged view

    Fig. View of the lock cylinder positions: 1 - Hold/Stop, 2 - Drive, 3 - Start. Insert a 1.2mm steel wire into the hold next to the ignition key (arrow)

  14.  
  15. Disengage the securing lever of the lock cylinder using a 1.2mm diameter piece of steel wire, then and pull lock cylinder out of steering lock housing. Refer to the illustration for details.

    Click image to see an enlarged view

    Fig. Disengage the securing lever (3) of the lock cylinder using a suitable wire (2 - arrow), then pull the lock cylinder (1) out of the steering lock housing

  16.  

To install:

  1. Insert ignition key into lock cylinder and turn the key to the "Drive" position.
  2.  
  3. Disengage the securing lever using the steel wire, then insert the lock cylinder into the steering lock housing.
    NOTE
    When inserting the lock cylinder, make sure the connection for anti-theft immobilizer reading coil is in the guide of the steering lock housing.

  4.  
  5. Pull the wire from the lock cylinder, then check to be sure the lock cylinder is seated properly in the lock housing.
  6.  
  7. Attach the harness connector of the anti-theft immobilizer reading coil to lock cylinder, if equipped.
  8.  
  9. Install trim of steering column switch and steering wheel, as outlined in this section.
  10.  

 
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