(warning:long reply) Re: Ignition Switch

Peter Schulz peschulz at cisco.com
Wed Mar 13 09:26:33 EST 2002

At 08:52 AM 3/13/2002 -0500, RICHARD MEZIC wrote:
>My 1991 Audi 200 doesn't start.  The dash lights and "key-in buzzer"
>continue even after the ignition key is removed.  Sounds to me like its the
>ignition switch - not turning all the way to start, and not turning off all
>the way either.  (No tell-tale symptoms beforehand - hard to turn the key
>the last few days, etc. - no easy hints like that.)

Oh boy...
Deja Vu all over again.

>Is this a drastically hard procedure.  ie, do I have to remove the steering
>wheel, drop the column, remove the dash, etc... to get to it?

Drastically hard?
Time consuming and occasionally frustrating?

Special tools required? Yes.
Removal of airbag and steering wheel? Yes.

Drilling required to replace lock cylinder?
maybe - if you are lucky, only the ignition switch is broken.
If you are not so lucky, you will also have to replace the lock
cylinder.  And unless you want to have two different keys for your Audi, a
locksmith will have to rekey the new lock cylinder (Figger around $40)

>I'm assuming it's actually the electric switch module behind the key
>cylinder lock, and not the lock itself?  <$50 for a new one?
>On the bright side, this may be an opportunity to have the critical points
>on the dashboard resoldered...

See old email attached- look at the bright side - at least you weren't
driving you wife home from the hospital with your new born son (I was)
I'll see what i can do about getting some of the pictures that i took scanned.



To: 200q20v <200q20v at audifans.com>
Cc: Dan Simoes <dans at audifans.com>, maximum at weetamoo.com, C1J1Miller at aol.com,
         copley one <copley at snet.net>
Subject: [200q20v] The Audi (Gods) are watching over Alex? (broken ignition

Picked up a second 200q20v Avant about a week ago...Titanium Grey/Platinum
with about 168Kmiles...

The previous owner gave me two different keys - "I had to replace the
ignition (key) switch"...

I thought Hmm, our Indigo Wagon has 162K miles on it...

Picked my wife and newborn son Alex up from the hospital in the Indigo
wagon, and stopped for a sandwich on the way home.

Go to start the wagon - I turn the key to the right, feel and hear a
"pop"  lights come on, but no start.
Take the key out and the lights are still on.


My wife doesn't know whether to cry or rip my head off (Ain't postpartem
depression great ;^)

I'm able to get in touch with her parents to pick her and Alex up, and I
call AAA for a flat bed.

Miracle of miracles, I get home with the car on the flat bed 5 minutes
after she does...and the driver helps me push the car into my garage.
I tip him accordingly.

I then call Mssrs  Paul Royal and Chris Miller to appraise them of the
situation.  Chris orders a new ignition switch for me from Mac at  Clair
Parts Connection.

I spend the rest of the day getting intimate with the interior of the
indigo wagon-with Mr Bentley close at hand.  Steering wheel removal went
easier than I thought.  Pulled out instrument cluster thinking that I could
get to the switch from the top.  No go.

Pull out the knee pad, and proceed to remove the column and support, only
to realize that the support doesn't need to be removed - I then retighten
it.  Removed the multifunction switch cluster. Removed the two 13mm nuts
hold the crushable column section.  Put a block of wood on the column front
and gently tapped it with a hammer - the column slid backwards towards the
firewall. I rotate the column and try to remove the switch assy.  Discover
that it's held in place with a security torx bolt.  I have hex wrenches. I
have torx wrenches and sockets.  But not security torx.


Off to Sears hardware where I luckily find the right bits.

Back to the car - removed the security bolt and pull the switch assembly-
and take it apart.  Find that not only the switch, but the end of the lock
cylinder is broken.  Back on the phone to Mac - luckily they had one lock
cylinder remaining in stock.

Next day, drive to Clair, pick up parts - and decide that I don't want to
deal with having two different keys for the car - SO I have to go to a
locksmith. $40 later it's rekeyed to match the rest of the car.

Stopped to touch up the solder joints on the instrument cluster, and dabbed
Stabilant 22 on the connectors.

Reassembly so to speak was the reverse of removal....I took pix and I will
give them to Chris to add to his website.

Hope things get better, or maybe its just sibling rivalry between 20v wagons?


ps>  later Kim says " had some trouble with the key and steering lock on
last Friday, but I forgot to tell you..."

Peter Schulz
1990 CQ
1991 200 20v TQW indigo mica
1991 200 20v TQW titanium grey
Chelmsford, MA USA
peschulz at cisco.com

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