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.
Remote Control Door Lock Receiver Replacement
Callout
Component Name
Preliminary Procedure
Remove the windshield outside moistu ...
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:
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If you cannot feel temperature change or pain to the skin, the seat heater
may cause burns. To reduce the risk of burns, people with such a condition should
use care when using the seat heater, especially for long periods of time. Do not
place anything on the seat that insulates again ...
Instrument Panel Knee Bolster Replacement
Instrument Panel Knee Bolster Replacement
Callout
Component Name
Preliminary Procedures
Disable the SIR system. Refer to SIR Disabling and Enabling.
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...
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Driver or Passenger Seat Cushion Frame Replacement
Callout
Component Name
Preliminary Procedures
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Remove the front seat cushio ...
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