Steering Column & Steering Column Switches - Cavalier & Sunfire Chevrolet Cavalier III

DESCRIPTION & OPERATION

COLUMN DESIGNATIONS

Steering columns are designated as fixed column or tilt column, and as column shift or floor shift. All automatic transaxle models, use a park lock cable system. Manual transaxle models, use a push button lock cylinder, and a clutch start switch.

COLUMN COLLAPSE FEATURE

Steering column is designed to collapse if impacted during a collision. Steering shaft and column jacket are both 2-piece units which are internally injected with plastic. The plastic protrudes from holes in each unit, keeping 2 separate pieces together as one unit. (Scheme 8) If the column or steering wheel is forcefully impacted, plastic pieces break off, allowing column and shaft to collapse.

PARK LOCK CABLE SYSTEM (A/T)

Park lock cable system prevents shift lever from being moved out of Park unless ignition lock cylinder is out of LOCK position and the lock cylinder from being turned to LOCK position unless shift lever is in Park. This is accomplished by a park lock cable connected between lock cylinder and shift lever.

BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI) SYSTEM

This system does not allow shift lever to be moved out of Park unless brake pedal is pressed. With brake pedal released and ignition on, current flows through BTSI solenoid to ground, energizing solenoid. With solenoid energized, a lock pawl protrudes from solenoid, preventing shift lever from being moved.

With brake pedal pressed, current flows through stoplight switch to ground side of solenoid. Under this condition, battery voltage is available on positive and negative sides of solenoid. This causes solenoid to de-energize, releasing lock pawl.

SERVICE PRECAUTIONS

Observe the following precautions when servicing air bag system

1. Disable air bag system before attempting any repairs to steering column or components. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__disabling-activating-air-bag-system) .
2. Sensing and Diagnostic Module (SDM) retains back-up voltage for about 10 minutes after air bag system is disabled. To avoid accidental air bag deployment, wait at least 10 minutes after disabling air bag system before working on vehicle components.
3. Always wear safety glasses when working around air bag system.
4. Always carry a live (undeployed) air bag with trim cover facing away from your body. This minimizes chance of injury if air bag accidentally deploys.
5. Place live (undeployed) air bag on bench or other surface with trim cover facing up, away from surface. This will reduce motion of air bag if it accidentally deploys.
6. DO NOT probe air bag inflator module connectors. Air bag may accidentally deploy.
7. DO NOT attempt repair of any air bag system components. Replace any faulty components as required.

DISABLING & ACTIVATING AIR BAG SYSTEM

1. Before proceeding, follow air bag service precautions. See «SERVICE PRECAUTIONS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__service-precautions) . Ensure front wheels are pointing straight ahead. Turn ignition to OFF position, and remove key. Remove left side instrument panel (I/P) wiring harness junction block access panel. Remove air bag fuse from left side I/P wiring harness junction block.
2. Remove Connector Position Assurance (CPA) from inflatable restraint steering wheel module coil connector, located above left side I/P wiring harness junction block. Disconnect connector. Remove right side I/P wiring harness junction block access panel. Remove CPA from inflatable restraint I/P module connector, located above right side I/P wiring harness junction block. Disconnect connector. Air bag system is disabled.
3. To activate air bag system, connect inflatable restraint instruments panel module connector, located above right side I/P wiring harness junction block. Install CPA. Install right side I/P wiring harness junction block access panel.
4. Install air bag fuse into left side I/P wiring harness junction block. Install left side I/P wiring harness junction block access panel. Staying well away from both air bags, turn ignition on. AIR BAG indicator will flash 7 times, and then turn off. If AIR BAG warning indicator does not function as described, a malfunction exists in air bag system.

ADJUSTMENTS

Note. Use illustrations for exploded view of steering column. (Scheme 9)or (Scheme 10).

CENTERING SIR COIL ASSEMBLY

Note. There are 2 different styles of coils. One rotates clockwise and the other rotates counterclockwise. If column is allowed to rotate when disconnected from steering gear, or centering spring is pushed down allowing hub to rotate while SIR coil is removed, perform following procedure. New coil assemblies are centered and held in position with a plastic tab. Remove tab after coil assembly is installed.

1. Ensure front wheels are in straight-ahead position. Hold coil assembly with clear bottom upward to see coil ribbon. While holding coil assembly housing and pressing spring lock, rotate hub in direction of arrow (on bottom of assembly) until it stops. Coil assembly should now be wound up snug against center hub.
2. Rotate coil assembly hub in opposite direction about 2 1/2 turns. Release spring lock between locking tabs in front of arrow. (Scheme 1) Coil assembly can now be installed if wheels are in straight-ahead position.

Scheme 1

System Check

1. Tilt column to full up position. Ensure parking brake is set. Turn lock cylinder to OFF-LOCK position. Remove key. Try to move shift lever out of Park. If shift lever can be moved out of Park, perform appropriate procedure under «ADJUSTMENTS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__adjustments) .
2. Insert key. Turn lock cylinder to RUN position. Try to move shift lever out of Park. If shift lever can be moved out of Park, perform appropriate procedure under «ADJUSTMENTS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__adjustments) . Depress brake pedal. Move shift lever to Neutral. If shift lever cannot be moved out of Park, perform appropriate «ADJUSTMENT»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__adjustments) procedure.
3. Try to turn lock cylinder to OFF-LOCK position. Ignition switch should stop turning before reaching the OFF-LOCK position, and the key should not be able to be removed. If system does not operate as specified, perform appropriate procedure under «ADJUSTMENTS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__adjustments) .
4. With key in same position as in previous step (just before OFF-LOCK position), place shift lever in Park. Turn lock cylinder toward RUN position, then to OFF-LOCK position. Remove key. Insert key. Tilt column to full down position and repeat all steps of «SYSTEM CHECK»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__system-check) . If system cannot be operated as specified, perform appropriate procedure under «ADJUSTMENTS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__adjustments) .

Adjustment (Column Shift)

Turn lock cylinder to RUN position. Place shift lever in Park. Unlock park lock cable adjuster at linear shift base adapter. (Scheme 2) Push and hold cable housing toward shifter assembly. Turn lock cylinder to OFF-LOCK position and pull key halfway out. Release cable housing and allow park lock cable to balance out. Lock cable adjuster. Perform SYSTEM CHECK.

Note. Ensure park lock cable locking tab is fully seated into ignition cylinder lock housing. Replace cable if lock tab is damaged.

Adjustment (Floor Shift)

Remove console. Place shift lever in Park. Unlock park lock cable adjuster at base of shift lever. (Scheme 3) Turn lock cylinder to RUN position to energize BTSI solenoid. Compress adjuster body fully and release to ensure BTSI solenoid is fully activated. Lock park lock cable adjuster. Turn lock cylinder to OFF-LOCK position. Recheck BTSI system. If system does not operate as specified, repeat adjustment procedure.

Scheme 2

Scheme 3

REMOVAL & INSTALLATION

Note. Use illustrations for exploded view of steering column. (Scheme 9)or (Scheme 10). Before servicing steering column, place shift lever in Park, turn lock cylinder to OFF-LOCK position and remove key.

Before proceeding, follow air bag service precautions. See SERVICE PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove air bag screws from back of steering wheel using No. 30 Torx bit. Remove CPA clip and disconnect electrical connector. Remove air bag module. To install, reverse removal procedure. Tighten mounting screws to 89 INCH lbs. (10 N.m).

1. Disconnect negative battery cable. Remove air bag. See «AIR BAG (INFLATOR) MODULE»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire) . Remove horn contact wire from steering column. Mark steering wheel hub in relation to steering shaft for installation reference. Remove steering wheel hexagonal locking nut. Using Steering Wheel Puller (J-1859-A), remove steering wheel.
2. To install, reverse removal procedure. Align marks on steering wheel and shaft. Tighten locking nut to 30 ft. lbs. (41 N.m). Activate air bag system. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__disabling-activating-air-bag-system) .

Remove steering wheel. See STEERING WHEEL . Remove upper and lower column covers. Turn lock cylinder to RUN position. Press locking button on back of column housing. Remove lock cylinder and lock cylinder preload spring. To install, reverse removal procedure. Ensure lock cylinder is in RUN position. Align locking tab with housing and press lock cylinder into position.

Remove steering wheel. See STEERING WHEEL . Remove upper and lower column covers. Disconnect harness from ignition switch. Remove 2 screws retaining ignition switch to rear of lock cylinder housing. Remove ignition switch. To install, reverse removal procedure. Tighten mounting screws to 12 INCH lbs. (1.4 N.m).

Remove steering wheel. See STEERING WHEEL . Firmly grasp tilt lever (if equipped) and turn counterclockwise to remove. Remove upper and lower column covers. Remove combination switch screws and disconnect switch electrical connectors. To install, reverse removal procedure. Apply Loctite 201 to threads of tilt lever.

Remove steering wheel. See STEERING WHEEL . Firmly grasp tilt lever (if equipped) and turn counterclockwise to remove. Remove upper and lower column covers. Remove wiper/washer switch screws and disconnect switch electrical connectors. To install, reverse removal procedure. Apply Loctite 201 to threads of tilt lever.

1. Set front wheels in straight-ahead position. Turn lock cylinder to LOCK position. Disconnect negative battery cable. Remove lower instrument panel sound insulators and trim panels as necessary.
2. Remove steering wheel. See «STEERING WHEEL»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire). Firmly grasp tilt lever (if equipped) and turn counterclockwise to remove. Remove upper and lower column covers. Disconnect electrical connectors from combination, ignition and wiper/washer switches.
3. Turn lock cylinder to RUN position. On floor shift, disconnect park lock cable from lock cylinder housing by pressing locking button and pulling cable from slot. (Scheme 3) On column shift, disconnect shift control cable from shift lever.
4. On all models, at floor/firewall, pull lower steering column shaft cover boot upward onto column in order to access flexible joint pinch bolt. Remove pinch bolt from lower steering column shaft. Support steering column while removing upper column bracket support bolts. Remove steering column from vehicle.
5. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/ignition-switchsteering-lock/#steering-column-steering-column-switches-cavalier-sunfire__torque-specifications).

OVERHAUL

Note. Use exploded view illustrations for overhaul of steering column. (Scheme 9)or (Scheme 10). Perform overhaul procedures with column removed from vehicle, and with steering wheel, combination switch and wiper/washer switch removed from steering column. Step 1 of disassembly procedure can be performed with column in vehicle if necessary.

Disassembly (Fixed Column)

1. Remove Supplemental Inflatable Restraint (SIR) coil assembly retaining ring. Remove SIR coil, wave washer and wire restraint clip. Using Lock Plate Compressor (J-23653-SIR) compress shaft lock, remove and discard shaft lock retaining ring. (Scheme 4) Remove shaft lock and turn signal cancel cam. Remove upper bearing spring and spacer.
2. On column shift, place lock cylinder in RUN position, press locking tab on park lock cable and remove from bearing and housing assembly. Pry locking tab on liner shift base and remove cable from shift base and park lock latch. Remove interlock solenoid. Move shift lever to Neutral, release shift lever spring tension. Remove clip, pin, spring and shift lever. Remove linear shift lever base from column. Disconnect shift cable from ball stud.
3. On all models, remove column jacket bushing. Pull steering shaft out from lower end of column jacket. Remove screws securing column housing to support mounting adapter. Separate column housing from support mounting adapter. Remove mounting plate and bearing retainer from column housing.

Scheme 4

Disassembly (Tilt Column)

1. Remove Supplemental Inflatable Restraint (SIR) coil assembly retaining ring. Remove SIR coil, wave washer and wire restraint clip. Using Lock Plate Compressor (J-23653-SIR) compress shaft lock, remove and discard shaft lock retaining ring. (Scheme 4) Remove shaft lock and turn signal cancel cam. Remove upper bearing spring, inner race seat and inner race.
2. On column shift, place lock cylinder in RUN position, press locking tab on park lock cable and remove from bearing and housing assembly. Pry locking tab on liner shift base and remove cable from shift base and park lock latch. Remove interlock solenoid. Move shift lever to Neutral, release shift lever spring tension. Remove clip, pin, spring and shift lever. Remove linear shift lever base from column. Disconnect shift cable from ball stud.
3. On all models, pull tilt lever bracket. Tilt column upward. Insert Phillips screwdriver into square opening of tilt spring retainer. Push spring retainer down and turn counterclockwise to release retainer. Remove retainer, spring guide and tilt spring. Place shift lever in Park. Using Pivot Pin Remover (J-21854-01), remove pivot pins. (Scheme 5)
4. Pull tilt lever to release bearing and housing from dowel pins. Remove bearing and housing assembly. Remove steering shaft. Remove jacket bushing assembly (or position sensor and bushing). Remove screws securing housing support to column jacket. Separate housing support from column jacket.
5. Mark upper race and shaft to lower shaft for reassembly reference. Note orientation of upper shaft to lower shaft. With block tooth on upper shaft at 12 o'clock position, lower shaft pinch bolt groove is at 6 o'clock position. Position upper and lower sections of steering shaft at a 90-degree angle to each other.
6. Separate upper and lower shafts. Rotate centering sphere 90 degrees. Remove sphere from shaft. Separate sphere halves. Remove joint preload spring.

Scheme 5

Inspection (Column Jacket)

Note. Vehicles involved in an accident with frame damage, major body damage, or impact to steering column may have a damaged or misaligned steering column. Use the following inspection procedures to determine if steering column has been damaged.

1. Check capsules on steering column bracket assembly. Capsules should be securely seated in bracket slots. (Scheme 6) If looseness is detected when pushed or pulled by hand, replace bracket if bracket is bolted onto column jacket, or replace column jacket if bracket is welded onto column jacket.
2. Measure distance between specified points on column jacket. (Scheme 7)or (Scheme 8). If distance measured is not 3.47-3.49" (88.11-88.61 mm), replace column jacket.

Inspection (Steering Shaft)

Inspect steering shaft for sheared injection plastic. (Scheme 8) If injection plastic is sheared, replace steering shaft. Check steering shaft runout by installing a dial indicator at lower end of steering shaft, then rotating steering wheel. If runout exceeds.063" (1.59 mm), replace steering shaft.

Reassembly

To reassemble, reverse disassembly procedure. Apply a thin coat of synthetic grease to all friction points when reassembling. Apply Loctite 201 to threads of tilt lever.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• SERVICE PRECAUTIONS
• DISABLING & ACTIVATING AIR BAG SYSTEM
• ADJUSTMENTS
• SYSTEM CHECK
• AIR BAG (INFLATOR) MODULE
• TORQUE SPECIFICATIONS