General Information: Overhaul Saturn ION I

Assembling and Coding Ignition Lock Cylinder

The ignition lock cylinder uses nine of the ten cut positions, 2 through 10. The ignition cylinder tumblers are all located on one side of the cylinder and not self-retaining. A retainer secures the tumblers. It follows the key code with the first tumbler being the first depth of the key code.

1. Hold the cylinder (1) so that the side with four tumbler spring wells is facing up.
2. The first tumbler (3) to be loaded will be the second key cut position, the second number in the key code. Install the first tumbler in the slot nearest the front of the lock cylinder.
3. Install the remaining tumblers following the key code.
4. Insert tumbler springs (4) into the spring wells on top of the tumblers.
5. Assemble the retainer (5) over springs. Secure by moving cylinder material over edges of the retainer with either a flat head screwdriver or center punch on each of the four corners over the ends of the retainer.
6. Check for correct loading of the tumblers by inserting the key into cylinder. The side bar (2) should be flush with the lock cylinder body diameter.
7. Lightly lubricate the tumbler surfaces using the provided lubrication.
8. Rotate lock to the run position.
9. Insert lock in steering column. Ensure both retainers are seated properly.
10. Rotate lock to key out position and remove key.

Assembling and Coding Door Lock Cylinder

The door lock cylinder only uses seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side four on one side and three on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on.

1. Hold the cylinder (11) so that the side with four tumbler spring wells faces up.
2. Insert tumbler springs (7) into the four spring wells.
3. Install the tumblers (6) for key cut position three in the slot nearest to the front of the lock cylinder.
4. Install the three remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder.
5. Snap the tumblers into place with light hand pressure.
6. Check for correct loading of the tumblers by inserting the key into cylinder. All of the tumblers should be flush with the lock cylinder.
7. Turn the cylinder so that the side with three tumbler spring wells faces up.
8. Insert the tumbler springs into the three spring wells.
9. Install the tumbler for key cut position four into the slot nearest the front of the lock cylinder.
10. Install the two remaining tumblers for key cut positions 6 and 8 on this side of the lock cylinder.
11. Snap the tumblers into place with light hand pressure.
12. Check for correct loading of the tumblers by inserting the key into cylinder. All of the tumblers should be flush with the lock cylinder.
13. Lightly lubricate the tumbler surfaces using the provided lubrication.
14. Install the two springs (3) into the two spring wells in the head of the door lock cylinder.
15. Snap the shutter assembly (2) onto the cylinder.
16. Place the detent spring (5) into the spring well located on the side of the lock cylinder.
17. Carefully place the detent ball (4) on the detent spring.
18. Depress the detent ball and spring and insert the cylinder into the cylinder housing (8). Ensure the detent ball and spring is not dropped.
19. Assemble the lock cylinder cap (1) by aligning the notch in the cap with the large drain slot in the case. Press the cap into place with light hand pressure.
20. Install the lock pawl clip (9) assembly matching the orientation when the lock was removed.
21. Install the lock pawl E-clip (10) to retain the lock pawl.
22. Insert the key into the lock and function lock to ensure for proper installation and smooth operation.

Assembling and Coding Rear Compartment Lid Lock

The rear compartment lock cylinder only uses 7 of the 10 cut positions, 3-9. The tumbler positions are staggered from side to side, four on one side and three on the other.

1. Hold the cylinder (5) so that the side with the four tumbler spring wells faces up.
2. Insert the tumbler springs (4) into the four spring wells.
3. Install the tumblers (3) for key cut position three in the slot nearest to the front of the lock cylinder.
4. Install the three remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder.
5. Snap the tumblers into place with light hand pressure.
6. Verify for the correct loading of the tumblers by inserting the key into cylinder. All of the tumblers should be flush with the lock cylinder.
7. Turn the cylinder so that the side with three tumbler spring wells faces up.
8. Insert the tumbler spring into the three spring wells.
9. Install the tumbler for key cut position four into the slot nearest to the front of the lock cylinder.
10. Install the two remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder.
11. Snap the tumblers into place with light hand pressure.
12. Verify for the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flush with the lock cylinder.
13. Lightly lubricate the tumbler surfaces using the provided lubrication.
14. Install two springs (12) into the two spring wells in the head of the door lock cylinder.
15. Snap the shutter assembly (2) onto the cylinder.
16. Place the detent spring (6) into the spring well located on the side of the lock cylinder.
17. Carefully place the detent ball (1) on the detent spring.
18. Depress the detent ball and spring and insert the cylinder and insert into the cylinder case (7). Ensure the detent ball and spring is not dropped.
19. Install the lock cylinder cap (8) by aligning the notch in the cap with the large drain slot in the case. Press the cap into place with light hand pressure.
20. Install rod clip (10) in hole at end of pawl (9) to ensure it matches the assembly being replaced.
21. Install the lock pawl clip assembly matching the orientation when the lock was removed.
22. Install the lock pawl E-clip (11) to retain the lock pawl.
23. Insert the key into the lock and function lock to ensure for proper assembly and smooth operation.