Assembling and Coding the Ignition Lock Cylinder

The ignition lock cylinder uses nine of the ten cut positions, 1-9. The tumbler positions are staggered from side to side, five on one side and four on the other.

1. Hold the uncoded cylinder assembly (4) so the side with five tumbler spring wells is facing upward.
   Fig 1: Assembling and Coding the Ignition Lock Cylinder

   Courtesy of GENERAL MOTORS CORP.
   IMPORTANT: The ignition lock cylinder tumblers (2) are not self retaining and must be held in place if the key is not fully inserted into the lock cylinder, or until the tumbler retainer (1) is properly staked into the cylinder.
2. Insert one tumbler spring (3) into the five tumbler spring wells.
3. The first tumbler to be loaded will be key cut position, number 1. Determine the cut depth at this position and install the corresponding tumbler (2) into the tumbler slot nearest the front of the cylinder Assembly (5) the end where the key is inserted. It may be necessary to move the sidebar (4) already pre-assembled in to the uncoded cylinder assembly (5) out slightly to full install the tumbler (2) into the correct tumbler slot.
4. Install the 4 remaining tumblers on this side of the lock cylinder, key cut positions 3, 5, 7 and 9.
5. Inspect for correct loading of the tumblers (2) by inserting the key into cylinder (5). The sidebar (4) should be flush with the outside diameter of the cylinder (5).
6. Turn the cylinder (5) so that the side with the 4 tumbler spring wells is facing up. Remove the key.
7. Insert the tumbler springs (3) into the four tumbler spring wells.
Fig 2: Identifying Key Cutting Depths
Courtesy of GENERAL MOTORS CORP.
8. Install the tumbler (2) for the key cut position 2 into the slot nearest to the front of the lock cylinder.
9. Install the three remaining tumblers, key cut positions 4, 6 and 8, on this side of the lock cylinder.
Fig 3: Installing Tumbler For Key Cut Position 2 Into Slot
Courtesy of GENERAL MOTORS CORP.
10. Inspect for correct loading of the tumblers (2) by inserting the key into cylinder (5). The sidebar (4) should be flush with the outside diameter of the cylinder (5).
11. Lightly lubricate the tumbler (2) surfaces using the provided lubrication.
12. With the key inserted into the housing, install and carefully stake one tumbler retainer (1) into the recessed area (5) on the cylinder.
13. Turn over the cylinder and carefully stake the other tumbler retainer (1) into the recessed area (5) on the cylinder.