Chevrolet Sonic Repair Manual: Front Side Door Lock Cylinder Coding (Free Wheeling)
Special Tools
BO-49753 Assembly Tool
The door lock cylinder uses 8 of the 8?€‰cut positions. The tumbler positions
are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining,
and are not snap in.
Note:
All lock cylinders for side milled keys have right and left
tumblers. The location of the tooth of the tumbler determines whether it
is right of left. Illustrations in this procedure show the right tumblers
on the top and the left tumblers on the bottom. All tumblers are marked
1R, 1L, 2R, or 2L. The number being cut depth and the letter meaning right
or left.
- Hold the door lock cylinder?€‰(1) so the side with the 4?€‰tumbler spring
pockets faces up, pocket nearest to the cylinder head.
- Insert the tumbler springs?€‰(2) into the 4?€‰spring pockets. This side
uses left tumblers.
- Install the tumbler?€‰(3) for key cut position one in the slot nearest to
the front of the lock cylinder. Install the remaining tumblers, key cut positions
3, 5, and 7, following the key code and same process. Press the tumblers in
place until they are secure.
- Check the correct loading of the tumblers by inserting the key into the
cylinder. All tumblers should be flush with the lock cylinder body.
- Turn the cylinder so the side with the 4?€‰tumbler spring wells faces up.
This side uses right tumblers.
- Insert the tumbler springs into the 4?€‰spring pockets.
- The first tumbler closest to the front of the lock cylinder to be loaded
will be the second key cut position, the second number in the key code. Install
the remaining tumblers for the key cut positions 4, 6, and 8. Press the tumblers
in place until they are secure.
- Check the correct loading of the tumblers by inserting the key into the
cylinder. All tumblers should be flush with the lock cylinder body.
- Insert the key and lightly lubricate the cylinder body diameter and tumbler
surfaces and a small amount in the head of the cylinder using the supplied grease.
- Insert the sleeve?€‰(4) onto the cylinder assembly.
- Insert the clutch?€‰(5) and driver?€‰(6) onto the cylinder?€‰(1).
- Load the cylinder into the BO-49753 assembly tool so that the clutch?€‰(1)
indexes with the notch in the opening of the tool?€‰(2).
- Load the assembly tool with the lock cylinder into a vice and tighten the
vice ONLY enough to hold the tool and lock the cylinder in place.
- Insert the roll pin?€‰(7) into the driver?€‰(6) and install it using a 1/16?€‰inch
pin punch.
- Insert the buffer?€‰(8) in the case?€‰(9), verify the buffer is properly
seated.
- Install the free wheel pin?€‰(11) in the sleeve?€‰(4) and clutch?€‰(5) and
insert the assembly into the case?€‰(9).
- With the lock cylinder assembly installed in the case?€‰(9), install the
retainer?€‰(10) and stake the retainer in place using a small punch and hammer
to peen the case material onto the exposed ends of the installed retainer?€‰(10).
- Insert the key into the lock and function the lock to check for proper assembly
and smooth operation.
iii!
Front Side Door Check Link Replacement
Callout
Component Name
Preliminary Procedure
Remove the front side door trim panel. ...
The door lock cylinder uses 8 of the 8?€‰cut positions. The tumbler positions
are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining,
and are not snap in ...
Other materials:
Front Side Door Window Weatherstrip Replacement
Front Side Door Window Weatherstrip Replacement
Callout
Component Name
Preliminary Procedures
Remove front side door trim panel. Refer to Front Side Door Trim
Replacement.
Remove the outside rearview mirror. Refer to Outs ...
Tire and Wheel Removal and Installation
Special Tools
CH-41013 Rotor Resurfacing Kit
CH-42450-A Wheel Hub Resurfacing Kit
For equivalent regional tools, refer to Special Tools.
Removal Procedure
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the wheel cover ...
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant
Pipe Joint Compound
Note: Three types of sealer are commonly used in engines. These
are RTV sealer, anaerobic gasket eliminator sealer, and pipe joint compound.
The correct sealer and amount must be used in the proper location to prevent
oil leaks. DO NOT interchange the 3 ...
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