Body - Door Lock Cylinders Bind
03-068October 29, 2004
Applies To:
See VEHICLES AFFECTED
Door Lock Cylinder Binds
(Supersedes 03-068, dated April 20, 2004)
Updated information is shown with asterisks and black bars.
SYMPTOM
The key will not go into the door lock cylinder, or if it goes in, it will not turn.
PROBABLE CAUSE
The door lock tumblers are damaged or worn.
VEHICLES AFFECTED
CORRECTIVE ACTION
Remove the door lock cylinder, and replace the inner cylinder, springs, and tumblers.
PARTS INFORMATION
REQUIRED MATERIALS
WARRANTY CLAIM INFORMATION
In warranty: The normal warranty applies.
Failed Part: P/N 72185-S9A-003
H/C 6896716
Defect Code: 00503
Symptom Code: 07902
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Obtain the customer's key code from the iN (Key Code Inquiry). Refer to the Honda High Security key Codes book that comes with the Matrix H key cutting machine. Write down the applicable cutting code for the key code number. Make sure the corrections to the code book listed in Service Bulletin 01-077, Cutting Sidewinder-Type keys With the Matrix H key Cutting Machine, have been made.
2. Use the chart shown to write down the numbers found in the key code book.
3. Remove the door panel. Refer to the appropriate service manual or use ISIS keyword Door Panel.
4. Remove the plastic cover as necessary.
5. Raise the window glass fully.
6. Remove the lock cylinder.
^ For Civic, go to step 7.
^ For CR-V, go to step 8.
^ For Element, go to step 11.
7. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder and disconnect the cylinder rod. Then go to step 14.
8. Release the clip, detach the hook, and remove the lock rod protector.
9. Disconnect the outer handle rod and cylinder rod.
10. Pull down on the retainer clip with a hook-shaped tool. Remove the lock cylinder. Then go to step 14.
11. Pull the glass run channel away as necessary, and remove the bolt, then remove the center lower channel by pulling it downward.
12. Remove the access seal, and disconnect the outer handle rod and the cylinder rod.
13. Push the top of the retainer clip with a flat-tip screwdriver, and hold it. Release the retainer clip with a hook-shaped tool, then remove the lock cylinder. Go to step 14.
14. With the door lock cylinder out of the door handle remove the E-clip and the arm.
15. Try to insert the key into the cylinder and turn it.
^ If you can insert and turn the key, go to step 18.
^ If you cannot insert the key or turn it, go to step 16.
16. Carefully remove the spring and plastic retainer.
17. Using a small screwdriver, push down on the tip of the last tumbler to release it, then remove the cylinder from the housing, being careful not to drop any tumblers and springs. Use your thumb and forefinger to hold the tumblers in place. Then go to step 20.
18. While turning the key left and right and pushing on the rear of the inner cylinder to release the spring, slowly remove the cylinder from the housing.
19. Using your thumb and forefinger to hold the tumblers, remove the key from the inner cylinder, being careful not to drop any tumblers and springs.
20. *Using the key code from the iN that you have written down at step 2, build a new inner cylinder with new springs, new cylinder, and tumblers from the door lock cylinder kit. Make sure you put the appropriate numbered tumbler in the proper inner cylinder cavity. Apply a thin layer of Permalube to each tumbler to help lubricate and retain it.*
NOTE:
^ There are two types of tumblers. The "SUBLOCK" tumbler goes only in cavity A." The "DISC" tumbler goes in cavities "B" through "J."
^ Cavity "E" is empty on all cylinders.
^ If no key code can be found on the iN or with the Matrix H High Security key Codes Book, remove one tumbler at a time from the old inner cylinder, and match the number stamped on the old tumbler to a new tumbler from the kit. Insert the new tumbler and spring in the appropriate new inner cylinder cavity.
^ Do not use the old inner cylinder, springs, or tumblers.
^ Using your thumb and forefinger, hold the tumblers in place, insert the key in the cylinder and verify that all tumblers are flush with the cylinder. If not, double-check the key number, the cutting key code, the tumbler numbers, and the cavity locations.
NOTE:
If the key cannot be inserted, check the tumbler in the "J" cavity. It may be out of position.
21. Leave the key in the cylinder. Reinstall the plastic retainer and spring if you removed them in step 16. Hold the plastic retainer and spring on the housing, and insert the inner cylinder. Rotate it left and right to engage the spring to the inner cylinder. Make sure the spring is properly seated to the inner cylinder.
22. Install the arm with a new cylinder rod clip and a new E-clip.
23. Make sure the key can be inserted and removed easily, and that the cylinder turns with the key.
24. Remove the key. Reinstall the retainer clip in the door handle, and push the lock cylinder into place.
25. Civic: Reconnect the cylinder rod.
26. CR-V: Reconnect the cylinder rod, the outer handle rod, and the rod protector.
27. Element: Reconnect the cylinder rod, the outer handle rod, and the access seal. Reinstall the lower run channel.
28. Reinstall the plastic covering, and lower the window glass. Install the door panel.
29. Check that the door lock and handle operate smoothly.
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