Assembling and Coding Door Lock Cylinder

The door lock cylinder assembly has 7 positions, which accept springs and tumblers. It uses key cut positions 3 through 9. A cylinder is tumbled in the following manner.

Fig 1: Assembling & Coding Door Lock Cylinder (1 Of 2)
Courtesy of GENERAL MOTORS CORP.
1. Hold the cylinder so that the side with 4 tumbler spring wells (6) faces up.
2. Install the 4 tumbler springs (1) into the 4 tumbler slots (6).
IMPORTANT: The tumblers are self-retaining and are snapped in with light pressure.
3. Using key cut position 3, install the first tumbler (2) into the cylinder.
4. Using key cut position 5, install the second tumbler (3) into the cylinder.
5. Using key cut position 7, install the third tumbler (4) into the cylinder.
6. Using key cut position 9, install the fourth tumbler (5) into the cylinder.
7. Turn the cylinder so that the side with three 3 spring wells is up.
8. Using key cut position 4, install the fifth tumbler (10) into the cylinder.
9. Using key cut position 6, install the sixth tumbler (9) into the cylinder.
10. Using key cut position 8, install the seventh tumbler (8) into the cylinder.
11. Inserting the key can at this point check the correct loading of tumblers. All tumblers should come to flush with the outside diameter of the cylinder. This will allow the cylinder to turn within its housing.
Fig 2: Assembling and Coding Door Lock Cylinder (2 Of 2)
Courtesy of GENERAL MOTORS CORP.
12. Place the detent spring (2) into the spring well located on the side of the cylinder near the tail.
CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
13. Place the detent ball (7) on the spring and carefully insert the cylinder into the housing so that the ball fits in the "V" and the cylinder bottoms out.
14. When the cylinder bottoms out in the housing, remove the key while ensuring that the cylinder is not pulled out of the housing.
15. Insert the 2 plate springs (4) into the 2 spring wells in the head of the door cylinder.
16. Snap the shutter sub-assembly (5) to the cylinder by firmly pressing down on the face of the shutter making sure the shutter pin lines up with the corresponding pin pockets on the cylinder.
17. Insert the key.
18. Install the cap (6) by aligning the notch in the cap with the large drain slot in the housing and pressing the cap until it bottoms out and snaps onto the housing.
19. Position the microswitch (11) to the platform of the housing.
20. Locate the plunger toward the cylinder and snap the clamp (2) over the switch onto the housing.
21. Place the pawl (3) on the tail of the cylinder and secure it with the retaining ring (2) included in the master service kit.
22. Press the spindle clip (1) into the hole provided on the pawl (3).
23. After installation, review Power Door Locks Description and Operation in Doors, for proper operation.