Saturday, May 7, 2011

how to remove and install Ignition switch on Mazda 3?

Ignition Switch/Lock Cylinder


REMOVAL AND INSTALLATION



See Figures 1 and 2


CAUTION
Some models covered by this information may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Chassis Electrical .

The ignition lock is an integral component of the steering lock mechanism. If the ignition lock must be replaced, perform the following procedure.



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the ignition switch/lock cylinder assembly



Click image to see an enlarged view

Fig. Fig. 2: Remove the break-off head retaining bolts by chiseling a slot in the bolt, then removing them with a screwdriver

Millenia
  1. Disconnect the negative battery cable.
  2. Properly disarm the air bag system.
  3. Remove the rear console box, brake boot and center panel (disconnect the harness connectors).
  4. Remove the rear console.
  5. Remove the undercover, glove compartment and compartment cover.
  6. Remove the upper and lower steering column covers.
  7. Tilt the steering shaft down. Remove the cap and panel light control switch. Remove the meter hood mounting screws. Pull the meter hood forward to disengage the clips.
  8. Remove the instrument cluster,
  9. Remove the drivers side air bag and the steering wheel.
  10. Remove the combination switch.
  11. Remove the passenger side air bag mounting bolts, electrical connector and remove the air bag module.
  12. Remove the hood panel release lever. Pull the side panel forward to disengage the clips, remove the side panel.
  13. Remove the side covers.
  14. Remove the dashboard mounting bolts, pull the dashboard up and forward and remove.
  15. Remove the steering shaft.
  16. Remove the screw and the ignition switch and disconnect the ignition switch connector.
  17. Using a chisel and a hammer make a groove in the heads of the steering lock mounting bolts. Remove the bolts and the steering lock assembly.

To install:
  1. Install the steering lock mechanism to the steering column jacket. Make sure that the lock operates correctly. Install new mounting bolts and tighten the bolts till the heads break off.
  2. Reconnect the ignition switch connector to the ignition switch and install the ignition switch to the steering lock mechanism with the screw.
  3. Replace the dashboard close to its mounts and connect all harness connectors. Install all mounting bolts. Torque to 14-18 ft. lbs. (19-25 Nm).
  4. Install the side covers.
  5. Instal the side panels.
  6. Install the steering shaft and torque the mounting bolts to 12-16 ft. lbs. (16-22 Nm).
  7. Connect the passenger side air bag module electrical connector and replace the module to the dash and install the mounting bolts.
  8. Install the combination switch on the steering column.
  9. Install the steering wheel and drivers side air bag module.
  10. Install the instrument cluster.
  11. Install the meter hood.
  12. Install the upper and lower steering column covers.
  13. Install the glove compartment cover, compartment and the undercover.
  14. Install the rear console, bracket, center panel, brake lever boot and the rear console box.
  15. Reconnect the negative battery cable,
  16. Place the steering column securely on a workbench. Use a chisel and hammer to make slots in the head of the lock screws. Remove the screws.

ON MAZDA_3
  1. Disconnect the negative battery cable.
  2. If equipped, disarm and remove the air bag.
  3. Remove the steering wheel and the combination switch.
  4. Remove the steering column by performing the following:
    1. Remove the driver's side under dash covers.
    2. If equipped, disconnect the key interlock cable from the steering column.
    3. Detach any remaining electrical wire harness connectors from the column.
    4. Remove the upper column-to-dash mounting bolts. Support the steering column.
    5. Remove the intermediate shaft-to-steering column shaft coupling bolt and remove the steering column-to-firewall bracket bolts/nuts.
    6. Remove the steering column from the vehicle.

  5. Place the steering column securely on a workbench. Use a chisel and hammer to make slots in the head of the lock screws. Remove the screws.
  6. Remove the ignition lock assembly.

To install:
  1. Position the ignition lock and bracket on the steering column.
  2. Install the new screws until the head twists off. Make sure the lock operates properly while tightening the new locking screws.
  3. The remainder of the installation is the reverse of the removal procedure.

------------------

  • Turn the key to the "Lock" position. Disconnect the negative battery cable and set it aside, ensuring that it doesn't touch metal. Wait for one minute so the backup power supply depletes the stored power.

  • Loosen the hood latch pull knob's retaining nut, using the appropriate wrench. Pull the hood latch down and away from the bottom of the dash. Remove the driver's side undercover (dash) retaining screws, using the appropriate socket, then pull the cover down. Detach the air conditioning vent hose from the undercover, using the appropriate socket or screwdriver, depending on the type of clamp used to hold it on.

  • Look under the dash to find the orange and blue air bag clockspring wiring harness connectors. Unplug the connectors. If the passenger side has an airbag, unbolt the glove compartment, using the appropriate socket. Remove the glove compartment to gain access to the orange and blue connectors. Unplug the connectors.

  • Turn the steering wheel so that the wheels are straight ahead. Loosen the air bag module bolts on the bottom of the steering wheel, using the appropriate socket. Tilt the top of the air bag module outward. Unhook the airbag tether from the hook on the steering wheel. Remove the nuts that hold the airbag assembly, using the appropriate socket. Tip the top of the airbag outward.

  • Disconnect the horn and cruise control wiring harness connectors from the underside of the steering wheel. Mark the steering wheel and the shaft, so you can put the wheel on exactly how you took it off. Loosen and remove the steering wheel nut from the shaft, using the appropriate wrench.

  • Install the steering wheel puller onto the steering wheel. Tighten the puller's center bolt -- turn it clockwise -- to pull the steering wheel from the shaft. Remove the puller, then take the steering wheel off the shaft, feeding the clockspring wire through the steering wheel.

  • Remove the rest of the driver's side under-dash covers, using the appropriate socket. Unplug the wiring harness connectors from the steering column. Remove the four bolts that hold the steering column to the dash, using the appropriate socket. The bolts are under the steering column and the dash.

  • Remove the intermediate shaft-to-steering column coupling bolt, using the appropriate socket. Remove the steering column-to-firewall bracket bolts and nuts, using the appropriate sockets. Pull the steering column out .

  • Place the steering column on a workbench. Using the chisel and hammer, make slots in the head of the lock screws, then remove the screws, using the screwdriver. Remove the ignition lock assembly.

  • Position the ignition lock and the bracket on the steering column. Install the new screws, twisting them in until the head twists off. As you are twisting the screws in, make sure the lock operates correctly, but turn the key in and out of the "Lock" position once the screws are in, and once again after the tops of the screws are twisted off.

  • Line up the steering column and install the column-to-firewall bracket bolts and nuts. Reinstall the coupling bolt. Ensure that the column is put in exactly as you took it out, else you will have steering problems. Reinstall the four column-to-dash bolts and tighten them firmly. Plug in the wiring harness connectors on the steering column and reinstall the under-dash covers.

  • Ensure that the wheels are still pointing straight ahead. Turn the clockspring all the way to the right. Turn the clockspring counterclockwise about 2 3/4 turns and align the marks, thus resetting the clockspring. Feed the wiring through the steering wheel and install the steering wheel. Tighten the steering wheel nut to 36 foot-pounds of torque. Reinstall the airbag and plug in the horn and cruise control connectors.

  • Ensure that the ignition switch is in the "Lock" position. Reconnect the orange and blue connectors under both sides of the dash. Reinstall the glove compartment and the rest of the dash under-covers. Reconnect the negative battery cable.

  • max