Key and Lock Cylinder Coding (1st Design, Ortech)

Key and Lock Cylinder Coding (1st Design, Ortech)

Special Tools
* BO-47869 Ignition Lock Cylinder Replacement Tool
* BO-48370 Lock Cylinder Cap Installer

Note: BO-47869 is used for the ignition lock cylinder. BO-48370 is used for the rear compartment lock cylinder.

Ignition Lock Cylinder

The ignition lock cylinder uses 7 of the 10 key cut positions, 4-10 when counting from the key head. The tumbler (8) orientations alternate in adjacent locations from side to side with 3 on one side and 4 on the other.





Warning

Wear safety glasses in order to avoid eye damage.

Note: The ignition lock cylinder tumblers (8) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder.

1. Hold the uncoded cylinder plug (5) positioned so the side with the sidebar slot is facing to the left and the 3 spring holes are on top.
2. Insert one tumbler spring (7) each into the 3 tumbler spring holes.
3. The first tumbler to be loaded will be key cut position number 5, the fifth number in the key code. Determine the cut depth at this position and install the corresponding tumbler (8) into the tumbler slot second from the front of the cylinder plug (5) (the end where the key is inserted).
4. In the same manner, determine the cut depth and corresponding tumbler and install the 2 remaining tumblers (8) into the tumbler slots located at key cut positions 7 and 9.
5. Check for correct loading by holding the tumblers (8) in position and fully inserting the matching key into the cylinder plug (5). All tumblers should be flush with the outside diameter of the cylinder plug.
6. Rotate the cylinder plug (5) so that the side with the sidebar slot is facing to the right and then remove the matching key. Remember the tumblers (8) are not self-retaining and must be held in place.
7. Insert one tumbler spring (7) each into the 4 tumbler spring holes.
8. The first tumbler to be loaded will be key cut position number 4. Determine the cut depth at this position and install the corresponding tumbler (8) into the tumbler slot nearest the front of the cylinder plug (5).
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers (8) into the slots located at key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (8) in position and fully inserting the matching key into the cylinder plug assembly (5). All tumblers should be flush with the outside diameter of the cylinder plug.
11. Lightly lubricate tumbler (8) surfaces using the lubrication provided.
12. Hold the cylinder plug (5) positioned so the side with the sidebar slot is facing to the left. Insert the U-shaped plunger shaft (6) into the grooves on the right side of the cylinder plug.
13. Install the cylinder plug assembly (5) into the cylinder sleeve assembly (4). There is a slight interference fit between the cylinder plug and the cylinder sleeve assembly, so be sure that the cylinder plug is fully seated into the bottom of the cylinder sleeve. The cylinder plug should be slightly below flush with the inner face of the cylinder sleeve. Once the cylinder plug assembly is fully installed into the cylinder sleeve assembly, the tumblers (8) will be fully enclosed and retained.




14. Install the actuator (11) into the pocket in the front face of the cylinder plug.
15. Install the security plate (10) on top of the cylinder plug in the cylinder sleeve assembly.





Caution: Refer to Fastener Caution (Fastener Caution).

16. Securely stake the security plate (10) into the cylinder sleeve assembly (4) by using the BO-47869 . Assemble the cylinder sleeve assembly, security plate, and BO-47869 . When loading cylinder sleeve assembly into the staking tool, ensure staking cup number 12 is positioned cup toward cylinder sleeve. Secure assembled staking tool in a vise. Rotate the forcing screw (13) in order to uniformly stake the cylinder sleeve material over the security plate.

Tighten the forcing screw (13) to 23-28 Nm (17-21 lb ft).




17. Once the security plate (10) has been staked to the assembly, ensure the actuator (11) can rotate freely inside the assembly by inserting a key and removing it.
18. Install and stake the cover (9) onto the head of the cylinder sleeve assembly (4) by crimping the cover material in 4 places into the pockets around the head of the cylinder sleeve. Ensure the cover is securely held onto the cylinder sleeve and that the key can be inserted into the cylinder sleeve assembly through the slot in the cover.
19. Install the sidebar (3) into the cylinder sleeve assembly (4).
20. Install the 2 sidebar springs (2) into the cylinder sleeve assembly (4).
21. Install the stake and the 2 sidebar spring retainers (1) onto the cylinder sleeve assembly (4) by crimping the material on the cylinder sleeve onto the sidebar spring retainers. Ensure the sidebar spring retainers are securely attached to the cylinder sleeve.
22. Insert the matching key into the cylinder assembly and confirm the following:

1. The sidebar drops to be flush or below flush with the outer diameter of the cylinder sleeve (4) when the matching key is fully inserted into the cylinder assembly.
2. The sidebar protrudes out of the diameter of the cylinder sleeve when the matching key is removed from the cylinder assembly.
3. With the matching keys installed, the plunger protrudes to be flush or almost flush with the rear of the cylinder sleeve.

23. Install the ignition cylinder assembly into the steering column of the vehicle

Door Lock Cylinder

The door lock cylinder only uses 7 of the 10 key cut positions, 4-10. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other are self-retaining. The left and right door lock cylinders are identical. The lever assembly determines which side of the vehicle the lock cylinder is for. After removing the current lock, record which lever is used and the orientation of the rod clip.




1. Rotate the cylinder (1) so the side with the 4 tumbler spring wells faces up.
2. Insert the tumbler springs (2) into the 4 spring wells.
3. Install the tumbler (3) for key cut position 4 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 6, 8, and 10, following the key code and same process. Press the tumblers in place until secure.
4. Check the correct loading of the tumblers by inserting the key into cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 3 tumblers spring wells faces up.
6. Insert tumbler springs into the 3 spring wells.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the fifth key cut position. Install the remaining tumblers for the key cut positions 7 and 9. Press the tumbler in place until secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flush with the lock cylinder body.
9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied grease.
10. Install 2 springs (4) into the spring wells in head section of lock cylinder.
11. Snap the shutter assembly (5) into the cylinder.
12. Place the detent spring (6) into the spring well located on the side of the cylinder.
13. Carefully place the detent ball (7) on the detent spring. Depress the detent ball into the cylinder and assemble into the case (8). Detent ball should rest in case slot at the front of the case.
14. Align dimples of the cylinder cap (9) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure.
15. If required, assemble rod clip to lever (10) using the recorded lever information.
16. Assemble lever to lock. Use E-clip (11) to retain lever assembly.

Note: The use of the detent ball (7) and ball spring (6) on the door assembly, if provided with the service kit, is optional.

17. Insert the key into the lock and function lock to check for proper assembly and smooth operation.

Rear Compartment Lid Lock Cylinder

The rear compartment lid lock cylinder uses 8 of the 10 key cut positions, 3-10 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on each side.





Note: The rear compartment lid lock cylinder tumblers (3) are not self-retaining and must be held in place if the key is not fully inserted into the lock cylinder or until the cylinder (1) is assembled into the case (4).

1. Hold the uncoded cylinder (1) positioned so the side with the drain hole is facing downward.
2. Insert one tumbler spring (2) each into the 4 tumbler spring holes.
3. The first tumbler to be loaded will be key cut position number 3, the third number in the key code. Determine the cut depth at this position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder (1), the end where the key is inserted.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers (3) into the tumbler slots located at key cut positions 5, 7, and 9.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching key into the cylinder (1). All tumblers should be flush with the outside diameter of the cylinder.
6. Rotate the cylinder (1) so that the side with the drain hole is facing upward and then remove the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into the 4 tumbler spring holes.
8. The first tumbler to be loaded will be key cut position number 4. Determine the cut depth at this position and install the corresponding tumbler (3) into the open tumbler slot nearest the front of the cylinder.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers into the tumbler slots located at key cut positions 6, 8, and 10.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching key into the cylinder (1). All tumblers should be flush with the outside diameter of the cylinder.
11. Lightly lubricate tumbler (3) surfaces using the lubrication provided.
12. With the matching key fully inserted into the coded cylinder, install the coded cylinder into the case (4).
13. Remove the matching key being careful to keep the coded cylinder (1) fully inserted into the case (4).
14. Insert one shutter spring (5) each into the 2 shutter spring holes located on the front face of the cylinder (1).
15. Install the shutter assembly (6) into the recessed area on the front face of the cylinder (1). Be sure that the ends of the pin on the shutter assembly are positioned in the pin cavities located in the front face of the cylinder.





Note: Be careful not to scratch or dent the cosmetic surface of the cap or damage the lock cylinder in any way while staking the cap.

16. Stake the cap (7) onto the head of the case (4) by using the appropriate staking tool BO-48370 (a). Ensure proper orientation and set the cylinder assembly (14) (b), which includes the case (4), coded cylinder, shutter springs, and shutter assembly and the cap (7) into the staking cup (15) and clamp into vise. Remove any debris and install the cleaned staking ram (16) into staking cup (15) and with a dead blow hammer, hit the staking ram (16) with moderate force 2 or 3 times. Check to determine if cap is securely staked to the cylinder assembly (14) (b). Repeat previous step until cap is securely staked to the cylinder assembly 14 (b). Remove assembly from the staking cup (15). If necessary, insert the removal punch (17) into the opposite end of the staking cup and tap lightly. Confirm that the shutter springs push the shutter assembly up against the inside surface of the cap (7).




17. Install the gasket (8) over the end of the cylinder assembly and slide it all the way up the case (4) until it seats behind the cap (7).
18. Install the return spring (9) over the back end of the cylinder (1) with the straight hook facing the rear of the case (4). Engage the straight hook of the return spring with the hook feature on the rear of the case.
19. Install the spacer (10) and lever (11) onto the end of the cylinder (1).
20. Install the retaining ring (12) in the groove at the end of the cylinder (1) to secure the lever (11) to the cylinder. Engage the bent hook of the return spring (9) with the lever.
21. Install the theft deterrent switch (13) onto the end of the cylinder (1) and snap the switch legs onto the case (4). Be sure the theft deterrent switch is engaged with the end of the cylinder and is securely attached to the case.
22. Check the operation of the lock assembly. The return spring (9) should provide a counterclockwise snap back.