1998-2001 J-Car - Cavalier/Sunfire - Procedure A (All Engine)

1998-2001 J Car - Cavalier/Sunfire - PROCEDURE A (all engines)

1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel.

2. Remove the 7 mm hex head screws that attach the left side insulator panel below the I/P and reposition the panel.

3. Remove the Connector Position Assurance (CPA) from the yellow SIR connector(s) that are clipped to the metal I/P brace near the bottom of the steering column.

4. Disconnect the yellow connectors.

5. If equipped, remove the tilt column lever.

6. Remove the three screws attaching the lower steering column cover and remove the cover.

7. Remove the upper steering column cover.





8. Remove the two TORX(R) head screws (2) that attach the ignition switch (3) to the column (1).

9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch.

10. Connect the electrical connectors to the new ignition switch.

Notice:
The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used:

^ Place the screw into position and with slight pressure, rotate the screw in a counterclockwise (loosening) direction.

^ When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw.

11. Position the new ignition switch to the column and install the two attaching TORX(R) head screws.

Tighten

Tighten the screws to 4 Nm (35 lb in).

12. Install the upper steering column cover.

13. Install the lower steering column cover and attaching screws.

Tighten

Tighten the screws to 4 Nm (35 lb in).

14. If equipped, install a new tilt lever.

15. Connect the two yellow SIR connectors at the base of the steering column.

16. Install the CPA in each connector and clip the connector(s) to the I/P brace.

17. If equipped, position the left side insulator panel to the bottom of the I/P and install the attaching screws.

Tighten

Tighten the screws to 2 Nm (18 lb in).

18. Install the AIR BAG fuse and install the fuse panel cover.

19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out.