Here's a general overview of the process. Specific steps may vary slightly depending on the exact model and trim level of your Sunbird. Always consult a repair manual specific to your vehicle year and model for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket set (various sizes)
* Screwdrivers (Phillips and flathead)
* Pliers
* Wire strippers/crimpers (if replacing wires)
* Multimeter (to test circuits - highly recommended)
* Possibly a steering wheel puller (depending on access)
Steps (General Outline):
1. Disconnect the Battery: This is CRUCIAL to prevent electrical shorts and injury. Disconnect the negative (-) terminal first.
2. Steering Wheel Removal (Possibly): You may need to remove the steering wheel to gain access to the ignition switch. This requires a special steering wheel puller and knowledge of how to do it safely. Consult your repair manual for this step.
3. Access the Ignition Switch: The ignition switch is typically located behind the steering column. You may need to remove trim pieces, screws, and possibly the steering column shroud to access it. Your repair manual will show you exactly where it is and how to get to it.
4. Remove the Old Ignition Switch: This usually involves removing screws or a retaining clip holding the switch in place. Carefully note the position of wires and connectors before disconnecting them. Take pictures if necessary.
5. Transfer Components (if applicable): Some components, such as the ignition cylinder (the part you put the key into), may be reusable. If so, carefully remove them from the old switch and install them on the new switch.
6. Install the New Ignition Switch: Secure the new switch in its mounting location using the screws or retaining clip.
7. Reconnect Wiring: Carefully connect all the wires to the new switch. Match them precisely to the way they were connected on the old switch. Double-check your connections! Incorrect wiring can cause the car not to start, or worse, create electrical shorts. Use your multimeter to ensure you've got the correct connections. The repair manual is vital here.
8. Reconnect Battery: Reconnect the positive (+) battery terminal.
9. Test: Try the ignition switch. Check all positions (accessories, ignition, start).
10. Reassembly: Reinstall any removed parts, including the steering wheel (if removed) and trim panels.
Important Considerations:
* Wiring Diagram: A wiring diagram is essential to ensure proper reconnection of the wires. Without one, you're working blind and risking damage.
* Ignition Cylinder: The ignition cylinder is often keyed to the vehicle. You might need to have a new key cut to match your car, or reuse the existing one.
* Security Systems: Some Sunbirds had anti-theft systems. Disconnecting the battery might trigger the alarm. Consult your owner's manual about disabling the alarm temporarily.
* Professional Help: If you're not comfortable with any of these steps, it's best to seek professional help from a qualified mechanic. The cost of repair is far less than the potential cost of damaging your vehicle's electrical system.
This is a general guide. Referencing a repair manual specific to your 1991 Pontiac Sunbird is absolutely crucial for a successful and safe repair. Remember, safety first!
