Volvo 240/740/760/780/940/960 1990-1998

Ignition Lock Cylinder/Switch

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The ignition lock cylinder/switch is an integral unit. The lock cylinder turns inside the switch assembly, and makes contact with terminals inside the switch, determining which circuit to energize. Replacement of the separate components is not possible; they are replaced as an assembly.

REMOVAL & INSTALLATION



240 Series

The ignition lock cylinder is mounted on the steering column and incorporates a steering wheel lock to deter vehicle theft Removal of the lock assembly requires the removal of the steering column assembly.

  1. Disconnect the negative battery cable AND TAPE the cable end.
  2.  
  3. Remove the air bag assembly.
  4.  
  5. Remove the steering wheel.
  6.  
  7. Remove the contact reel.
  8.  
  9. Pull up the cover from the lower steering shaft joint, if required.
  10.  
  11. Loosen the upper bolts in the upper and lower joints.
  12.  
  13. Pull down the lower steering shaft so that the upper joint is freed from the upper steering shaft
  14.  
  15. Remove the upper and lower steering column covers.
  16.  
  17. Disconnect the connector for the wiper control.
  18.  
  19. Remove the retaining bolts for the wiper and indicator controls holder.
  20.  
  21. Lift the holder over the steering shaft and remove. Note the position of the indicator switch lead and remove.
  22.  
  23. Remove the connector from the starter switch, if required.
  24.  
  25. Remove the steering column's lower retaining bracket, seal in the firewall and defroster hose from the heater unit.
  26.  
  27. Tap the shearing bolts so that the bolts and plastic washers slide out of their slots in member.
  28.  
  29. Carefully remove the steering column with steering lock. Avoid getting the steering column caught while passing through the firewall.
  30.  
  31. Mount the steering column in a vise.
  32.  
  33. Break off the washers from the rear end edge of the shearing bolts, then using a pair of channel locks, remove the shearing bolts.
  34.  
  35. Press the ignition lock assembly from the steering column, using a suitable drift and counterhold tool (5295 or equivalent).
  36.  
  37. Install the key in the lock and turn.
  38.  

To install:
  1. Install the key in the lock and turn.
  2.  
  3. Press the new ignition lock assembly onto the steering column, using a suitable drift and counterhold tool (5295 or equivalent). The lock assembly, when installed, should be positioned as follows: Measure the distance from the top of the lock assembly to the end of the steering column, above splined area. The distance should be 5.98 inches (152mm).
  4.  
  5. Remove the key form the lock.
  6.  
  7. Turn the steering shaft and check that the lock barrel locks it.
  8.  
  9. Before installing the steering column, check that the upper steering shaft's collapsible coupling is intact. Its upper end (A) should not be able to move axially in relation to its lower end (B). Also, check the total length; it should be 27.38-28.18 inches (69.5-71.5cm). If the measurement is incorrect, replace the complete steering column.
  10.  
  11. Install the plastic guides in the column support. Turn the guides so that the washers faces downwards.
  12.  
  13. Install the steering column into position, but do not tighten the shearing bolts completely.
  14.  
  15. Pull the steering column towards the rear as far as possible; tighten the bolts further, but do not shear them yet.
  16.  
  17. Install the rubber grommets.
  18.  
  19. Install the lower retaining bracket and tighten the bolts lightly.
  20.  
  21. Coat the firewall rubber seals with petroleum jelly.
  22.  
  23. Install the seal on the steering column (cone turned inward) from the engine compartment side.
  24.  
  25. Tighten the upper bolts, but do not shear them yet.
  26.  
  27. Tighten the lower retaining bolts to 11-17 ft. lbs. (15-25 Nm).
  28.  
  29. Attach the defroster hose and reconnect the ignition lock connector.
  30.  
  31. Attach the universal joint to the upper steering column shafts. First tighten the upper bolt, then the lower.
  32.  
  33. Install the locking pins.
  34.  
  35. Checking and adjusting steering shaft:
    1. When checking, the distance (A) between the upper steering shaft joint and shoulder on the lower steering shaft should be 0.39-0.75 inch (10-19mm).
    2.  
    3. If incorrect, loosen the upper bolted at (B) the lower joint. Loosen the lower bolt (C) of the upper shaft universal joint. Adjust the distance (A), by moving the shaft up or down. Tighten the bolts (B and C) to 14-20 ft. lbs. (18-28 Nm).
    4.  

  36.  

Make sure the position of the upper steering shaft does not change, as this can affect the distance between the steering wheel and the steering column cover.

  1. Install the holder for the combination switch control and connect the leads.
  2.  
  3. Connect the ground lead to one of the retaining bolts.
  4.  
  5. Install the upper and lower steering column covers.
  6.  
  7. Set contact reel to zero position: If contact reel must be zero, turn the reel to the far right end and then back 3 revolution to the left. Lock the contact reel with the screw in the plastic strip.
  8.  
  9. Ensure the front wheels are perfectly in straight-ahead position.
  10.  
  11. Install the contact reel bracket and contact reel.
  12.  
  13. Reconnect and properly position the lead.
  14.  


WARNING
Do not turn the steering, as this will cause the pin to snap, requiring replacement of the contact reel.

  1. Install the steering wheel. Set the steering wheel so that the contact reel pin is in the center of the steering wheel hole.
  2.  
  3. Install the steering wheel nut finger-tight.
  4.  
  5. Remove the screw in the contact reel plastic strip and install in its parking hole in steering wheel.
  6.  
  7. Tighten the steering wheel nut to 42 ft. lbs. (60 Nm).
  8.  


CAUTION
When connecting the battery, make sure that no one is in the vehicle in case of an SRS malfunction causing accidental air bag deployment.

  1. Connect the negative battery cable.
  2.  
  3. Check the SRS lamp operation and that no fault codes have been registered.
  4.  

Except 240 Series

See Figures 1 and 2


WARNING
Before working the steering system, read the SRS service precautions in Chassis Electrical .

  1. Place the front wheels in straight-ahead position.
  2.  
  3. Disconnect the negative battery cable AND TAPE the cable end.
  4.  
  5. Remove the air bag assembly.
  6.  
  7. Remove the steering wheel.
  8.  
  9. Remove the contact reel assembly.
  10.  
  11. Remove the combination switch.
  12.  
  13. Remove the steering column rake adjustment lever using a 0.12 in. (3mm) hex wrench.
  14.  
  15. Remove the parking plate around the steering tube (4 screws).
  16.  
  17. Disconnect the ignition lock connector.
  18.  
  19. Turn the ignition switch to position I .
  20.  
  21. Take a 0.079 inch (2mm) drift and press down the tumblers in the cylinder.
  22.  
  23. Remove the lock assembly.
  24.  

To install:
  1. Install the steering lock assembly.
  2.  
  3. Turn the ignition switch to position I and press down the tumblers with a suitable drift
  4.  
  5. Install the lock assembly.
  6.  
  7. Install the combination switch assembly.
  8.  
  9. Install the contact reel.
  10.  
  11. Install the steering wheel.
  12.  
  13. Install the air bag assembly.
  14.  


CAUTION
When connecting the battery, make sure that no one is in the vehicle in case of an SRS malfunction causing accidental air bag deployment.

  1. Reconnect the negative battery cable.
  2.  
  3. Check the vehicle operation and SRS system for fault codes.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the upper and lower steering column covers



Click image to see an enlarged view

Fig. Fig. 2: Ignition lock cylinder and switch removal

 
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