Question 1

How to replace the ignition lock cylinder and ignition switch assembly on Volvo 740?

Accepted Answer

The ignition lock cylinder/switch is an integral unit in which the lock cylinder rotates within the switch assembly, making contact with terminals which select which circuit to energize, and the replacement of the components must be done as an assembly. For the 240 Series, the ignition lock cylinder is mounted on the steering column and has a steering wheel lock to prevent theft of the vehicle, which requires the steering column assembly to be removed to access. Start with disconnecting the negative battery cable (tapping the end once with duct tape) and remove the air bag assembly, steering wheel and contact reel. If necessary, pull the cover from the lower steering shaft joint, loosen the upper bolts in the joints and pull down the lower steering shaft to free the upper joint. Remove the upper and lower steering column covers, disconnect the wiper control connector and remove the retaining bolts for the wiper and indicator controls holder. Lift the holder over the steering shaft, noting the position of the lead from the indicator switch, and remove the connector from the starter switch if necessary. Remove the lower retaining bracket of the steering column, seal in the firewall and defroster hose of the heater unit and tap the shearing bolts to slide it out. Carefully remove the steering column with the steering lock with it, avoiding catching it on the firewall as it passes through it. Mount the steering column in a vise, break off the washers from the shearing bolts and remove them with channel locks. Press the ignition lock assembly from the steering column with an appropriate drift and counterhold tool, insert the key in the ignition lock and rotate it, then press the new ignition lock assembly into the steering column, making sure to fit it into the right position. Remove the key, and check the lock barret locks the steering shaft, and check the integrity and length of the collapsible coupling. Install the plastic guides and position the steering column, tightening the bolts, but not shearing them. Install rubber grommets, lower retaining bracket and cover the firewall rubber seals with petroleum jelly and fit the seal on the steering column. Tighten the upper bolts and then the lower retaining bolts and reconnect the ignition lock connector. Mount the universal joint to the shafts of the upper steering column, install the locking pins, measure the distance between the upper steering shaft joint and the lower steering shaft. Install the holder for the combination switch control and connect the leads and ground the lead to a retaining bolt. Install the upper and lower steering column covers Set the contact reel to zero position, the front wheels should be straight, and the contact reel bracket should be installed. Reconnect and position the lead and the steering wheel has been installed and the steering wheel nut has been tightened. Finally, attach the negative battery cable and test the SRS lamp for any fault codes. For models other than 240 Series, position the front wheels in the straight-ahead position, disconnect the negative battery cable, remove the air bag assembly, the steering wheel, contact reel assembly, combination switch, and steering column rake adjustment lever. Remove the parking plate around the steering tube, disconnect the ignition lock connector, turn the ignition switch to position f, press down the tumblers in the cylinder and remove the lock assembly. To install, place the steering lock assembly, turn the ignition switch to position I, and press down the tumblers and install the assembly of the lock, and the combination switch, the contact reel, the steering wheel, and the air bag. Finally, reattach the negative battery cable and examine the vehicle operation and SRS system for fault codes.

Question 2

How to remove and refit the lock cylinder and ignition switch from the steering column on Volvo V40?

Accepted Answer

To remove the lock cylinder, you must first disconnect the battery negative lead. Release the height adjustment lever and undo the retaining screws and remove the upper and lower shrouds from the steering column. Insert the ignition key and turn the switch to position I. Depress the lock cylinder detent by inserting a 2mm punch into the hole of the lock housing, and withdraw the cylinder from the housing. For refitting, insert the key into the new lock cylinder, and turn the lock cylinder to position I. Depress the detent with the punch, and slide the lock cylinder all the way into position. Check the operation of the lock assembly and then clip the upper shroud firmly in place, refit the lower shroud and tighten its retaining screws firmly before reconnecting the battery negative lead. When removing the lock housing assembly, first remove the steering column and clamp it firmly in a vice by taking care not to distort the column tube. Using a hammer and appropriate punch, tap the lock housing retaining clamp bolts so that they can be unscrewed by hand or carefully drill the heads off the shear-bolts. Remove the bolts and the mounting clamp and lift the lock assembly out of the steering column. For refitting, engage the lock assembly to the column, refit the mounting clamp and screw in the new shear-bolts. Evenly and gradually tighten the shear-bolts to light tightness, check the working of the lock assembly to get it in the right position and then tighten both bolts till their heads shear off before refitting the steering column. To remove the ignition switch, disconnect the battery negative terminal, undo the height adjustment lever, undo the holding screws and remove the bottom shroud from the steering column. Undo the retaining screw and remove the switch assembly from the end of the lock housing, disconnect the wiring connector and remove the switch from the car. Refitting is the opposite of removal and it ensures that the switch insert is properly engaged with the lock cylinder pin.

Genuine Volvo Ignition Switch

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Volvo Ignition Switch Parts and Q&A

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