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Home >> Chevrolet >> 2003 >> Malibu Base >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panel, Gages, And Console >> Repair Instructions >> Ignition Switch Replacement >> Removal Procedure

Removal Procedure

CAUTION: Refer to BATTERY DISCONNECT CAUTION in Cautions and Notices.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
  2. Disable the SIR system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
  3. Remove the accessory trim plate from the I/P carrier. Refer to TRIM PLATE REPLACEMENT - INSTRUMENT PANEL (I/P) ACCESSORY  .
  4. Remove the instrument panel cluster from the I/P carrier. Refer to INSTRUMENT PANEL CLUSTER (IPC) REPLACEMENT  .
    Fig 1: Removing Ignition Switch Bolts From Ignition Switch
    G01590138Courtesy of GENERAL MOTORS CORP.
  5. Remove the ignition switch bolts from the ignition switch.
  6. Insert the key into the ignition switch lock cylinder.

    Rotate the key to the ON position.

  7. If the ignition switch lock cylinder is seized or won't rotate, perform the following procedure:
    1. 7.1. Protect the immediate work area with suitable material such as clean shop towels or a clean fender cover.
    2. 7.2. Locate the surface for the ignition switch lock cylinder release button (2) on the plastic ignition switch housing.

      On the key entry side of the switch housing center punch a location on the rib (1) approximately 3/8 of an inch from the cylinder release button (2).

    3. 7.3. Carefully drill a pilot hole through the plastic housing with a 1/8 inch drill bit.
    4. 7.4. Using a 9/32 inch drill bit carefully drill a hole at the pilot location, and slightly into the ignition switch lock cylinder surface to break the release button retaining spring.
      Fig 2: Locating Ignition Switch Lock Cylinder Release Button On Plastic Ignition Switch Housing
      G01590139Courtesy of GENERAL MOTORS CORP.
    5. 7.5. Remove portions of the broken spring from the hole using a small suitable tool.
    6. 7.6. Grasp the ignition switch lock cylinder and remove the cylinder from the switch housing.
    7. 7.7. Remove any plastic flashing from the drilling operation, and using compressed air blow out the ignition switch assembly.
  8. Disconnect the electrical connectors from the ignition switch.
  9. Release the transaxle park/lock cable retainer, then pull outward to remove the cable from the ignition switch.
    Fig 3: Disconnecting Electrical Connectors From Ignition Switch
    G01590140Courtesy of GENERAL MOTORS CORP.
  10. Press the ignition switch lock cylinder release plunger. The release plunger is located at the four o'clock position on the ignition switch housing.
  11. Use the key in order to pull the ignition switch lock cylinder from the ignition switch housing.
    Fig 4: Removing Ignition Switch Lock Cylinder From Ignition Switch Housing
    G01590141Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the pass key electrical connector from the ignition switch housing.
  13. Remove the ignition switch housing through the opening in the I/P cluster.
    Fig 5: Removing Pass Key Electrical Connector From Ignition Switch Housing
    G01590142Courtesy of GENERAL MOTORS CORP.