engine SATURN ASTRA 2008 Repair Manual

Fuses Usage
8 Horn
10 Door Locks
13 Foglamps
14Windshield Wipers
(high speed)
15Windshield Wipers
(low speed)
16Antilock Brake System,
Brake Lamp Switch
17 Vacuum Pump
18 Starter
20 Air Conditioning Clutch
21Engine Control
Module (ECM)
(Main Relay)
22 ECM (Battery)
24 Fuel Pump/InjectorsFuses Usage
26ECM (Sensor and
Actuators)
27 Power Steering
28Automatic
Transmission (Battery)
29Automatic
Transmission (Ignition)
30 ECM (Ignition)
32 Brake Switch
34Steering Column
Module
35 Radio
36OnStar™ Module/
OnStar™ Interface
Module/DisplayRear Compartment Fuse
Block
To open the liftgate, SeeLiftgate on
page 2-6.
The rear compartment fuse block is
located on the left side of the
cargo area behind a cover.
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(D) Maximum Cold Ination
Load Limit:Maximum load that
can be carried and the maximum
pressure needed to support
that load.
(E) Tire Ination
:The
temporary use tire or compact
spare tire should be inated
to 60 psi (420 kPa). For more
information on tire pressure
and ination seeInflation - Tire
Pressure on page 9-46.
(F) Tire Size
:A combination of
letters and numbers dene a
tire’s width, height, aspect ratio,
construction type, and service
description. The letter T as
the rst character in the tire size
means the tire is for temporary
use only.(G) TPC Spec (Tire
Performance Criteria
Specication)
:Original
equipment tires designed to
GM’s specic tire performance
criteria have a TPC specication
code molded onto the sidewall.
GM’s TPC specications meet
or exceed all federal safety
guidelines.
Tire Size
The following illustration shows
an example of a typical
passenger vehicle tire size.(A) Passenger (P-Metric) Tire
:The United States version of a
metric tire sizing system.
The letter P as the rst
character in the tire size
means a passenger vehicle tire
engineered to standards set by
the U.S. Tire and Rim
Association.
(B) Tire Width
:The three-digit
number indicates the tire section
width in millimeters from sidewall
to sidewall.
(C) Aspect Ratio
:A two-digit
number that indicates the tire
height-to-width measurements.
For example, if the tire size
aspect ratio is 60, as shown in
item C of the illustration, it would
mean that the tire’s sidewall is
60 percent as high as it is wide.
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CAUTION (Continued)
3. Turn off the engine and
do not restart while the
vehicle is raised.
4. Do not allow passengers to
remain in the vehicle.
To be certain the vehicle will
not move, put blocks at the
front and rear of the tire
farthest away from the one
being changed. That would be
the tire on the other side, at the
opposite end of the vehicle.
When you have a at tire, place the
wheel block at the tire diagonally
across from the at tire.
Removing the Spare Tire
and Tools
The equipment you will need is
located in the rear storage area.
1. Open the liftgate. SeeLiftgate on
page 2-6.
2. Lift the oor cover to access the
spare tire and tools.3. Remove the foam pad. Turn the
retainer counterclockwise to
remove it.
4. Remove the spare tire by pulling
it up and out of the trunk.
Vehicle Service and Care 9-61
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4. Open the hoods and locate the
batteries. Find the positive (+)
and negative (−) terminal
locations on each vehicle. Your
vehicle’s positive (+) terminal
is identied by “+” sign on battery
case or terminal.Engine
Compartment Overview on
page 9-6.
{CAUTION
An electric fan can start up
even when the engine is not
running and can injure you.
Keep hands, clothing and tools
away from any underhood
electric fan.
{CAUTION
Using a match near a battery
can cause battery gas to
explode. People have been hurt
doing this, and some have been
blinded. Use a ashlight if you
need more light.
Be sure the battery has enough
water. You do not need to add
water to the battery installed in
your new vehicle. But if a
battery has ller caps, be sure
the right amount of uid is
there. If it is low, add water to
take care of that rst. If you
don’t, explosive gas could be
present.
(Continued)
CAUTION (Continued)
Battery uid contains acid that
can burn you. Do not get it on
you. If you accidentally get it in
your eyes or on your skin, ush
the place with water and get
medical help immediately.
{CAUTION
Fans or other moving engine
parts can injure you badly.
Keep your hands away from
moving parts once the engine
is running.
Vehicle Service and Care 9-69
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5. Check that the jumper cables do
not have loose or missing
insulation. If they do, you could
get a shock. The vehicles
could be damaged too.
Before you connect the cables,
here are some things you to
know. Positive (+) will go
to positive (+) or to a remote
positive (+) terminal if the vehicle
has one. Negative (−) will go
to the engine lift hook.
Do not connect positive (+) to
negative (−) or you will get
a short that would damage the
battery and maybe other parts
too. And do not connect the
negative (−) cable to the
negative (−) terminal on the
dead battery because this can
cause sparks.6. Connect the red positive (+)
cable to the positive (+) terminal
of the dead battery. Use a
remote positive (+) terminal if
the vehicle has one.
7. Do not let the other end touch
metal. Connect it to the
positive (+) terminal of the good
battery. Use a remote positive (+)
terminal if the vehicle has one.
8. Now connect the black
negative (−) cable to the
negative (−) terminal of the
good battery. Use a remote
negative (−) terminal if the vehicle
has one.
Do not let the other end touch
anything until the next step.
The other end of the negative (−)
cabledoes notgo to the dead
battery.9. Connect the other end of the
negative (−) cable at least
18 inches (45 cm) away from
the dead battery, but not
near engine parts that move.
Connect it to the engine lift hook.
You may need to scrape the
surface with your jumper cable
to obtain a proper ground.
The electrical connection is just
as good there, and the chance
of sparks getting back to the
battery is much less.
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10. Now start the vehicle with the
good battery and run the
engine for a while.
11. Try to start the vehicle that had
the dead battery. If it will not
start after a few tries, it probably
needs service.
Notice:If the jumper cables are
connected or removed in the
wrong order, electrical shorting
may occur and damage the
vehicle. The repairs would not
be covered by your warranty.
Always connect and remove the
jumper cables in the correct
order, making sure that the cables
do not touch each other or
other metal.A. Heavy, Unpainted Metal Engine
Part or Remote Negative (–)
Terminal
B. Good Battery or Remote
Positive (+) and Remote
Negative (–) Terminals
C. Dead Battery or Remote
Positive (+) TerminalTo disconnect the jumper cables
from both vehicles, do the following:
1. Disconnect the black negative (−)
cable from the vehicle that had
the dead battery.
2. Disconnect the black negative (−)
cable from the vehicle with the
good battery.
3. Disconnect the red positive (+)
cable from the vehicle with the
good battery.
4. Disconnect the red positive (+)
cable from the other vehicle.
5. Return the caps over the
positive (+) and negative (–)
terminals to their original
positions. Jumper Cable Removal
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Technical Data
Vehicle Identication
Vehicle Identication
Number (VIN)..................10-1
Service Parts
Identication Label...........10-1
Capacities and
Specications
Capacities and
Specications..................10-2
Vehicle Identication
Vehicle Identication
Number (VIN)
This is the legal identier for your
vehicle. It appears on a plate in the
front corner of the instrument panel,
on the driver side. It can be seen
through the windshield from outside
the vehicle. The VIN also appears on
the Vehicle Certication and Service
Parts labels and the certicates of
title and registration.
Engine Identication
The eighth character in the VIN is
the engine code. This code helps
identify the vehicle’s engine,
specications, and replacement
parts. See “Engine Specications”
underCapacities and Specifications
on page 10-2for your vehicle’s
engine code.
Service Parts
Identication Label
This label is on the trunk oor.
It is very helpful if you ever need
to order parts. The label has
the following information:
Vehicle Identication
Number (VIN)
Model designation
Paint information
Production options and special
equipment
Do not remove this label from the
vehicle.
Technical Data 10-1
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Capacities and Specications
The following approximate capacities are given in English and metric conversions. See “Fluids and Lubricants” in the
index of the “Limited Warranty, Maintenance and Owner Assistance Information” manual.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant For the air conditioning system refrigerant charge amount, see the refrigerant caution label located
under the hood. See your dealer/retailer for more
information.
Cooling System Automatic Transmission 6.2 qt 5.9 L
Manual Transmission 7.3 qt 6.9 L
Engine Oil with Filter 4.8 qt 4.5 L
Fuel Tank 11.9 gal 45.0 L
Transmission Fluid Automatic Transmission 4.2 qt 4.0 L
Manual Transmission 1.6 qt 1.5 L
Wheel Bolt Torque 81 lb ft 110 Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual.
10-2 Technical Data
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Engine Specications
Engine VIN Code Transmission Spark Plug Gap
1.8L L4 1 Automatic
Manual 0.035 in (0.90 mm)
Technical Data 10-3
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Owner Publications
Information on how to obtain
product bulletins and as described
below is applicable only in the
fty U.S. states and the District
of Columbia, and only for cars and
light trucks with a Gross Vehicle
Weight Rating (GVWR) less
than 10,000 pounds (4 536 kg).
Copies of individual bulletins
are also at your participating Saturn
retailer. You can ask to see them.
In Canada, information relating
to product service bulletins can
be obtained by contacting your
Saturn retailer.
Service Bulletins
Saturn regularly sends its retailers
useful service bulletins about Saturn
products. Saturn monitors product
performance in the eld. We then
prepare bulletins for servicing our
products better. You can get these
bulletins, too.Bulletins cover various subjects.
Some pertain to the proper use and
care of your vehicle. Some describe
costly repairs. Others describe
inexpensive repairs which, if done on
time with the latest parts, may avoid
future costly repairs.
Some bulletins tell a technician how
to repair a new or unexpected
condition. Others describe a quicker
way to x your vehicle. They can
help a technician service your
vehicle better.
Most bulletins apply to conditions
affecting a small number of vehicles.
Your Saturn retailer or a qualied
technician may have to determine
if a specic bulletin applies to
your vehicle. To order Saturn
bulletins, call Saturn Publications
at 1-800-2-SATURN or visit
saturn-publications.com to order
online.
Vehicle Data
Recording and
Privacy
Your Saturn vehicle has a number of
sophisticated computers that record
information about the vehicle’s
performance and how it is driven.
For example, your vehicle uses
computer modules to monitor and
control engine and transmission
performance, to monitor the
conditions for airbag deployment and
deploy airbags in a crash and, if so
equipped, to provide antilock braking
to help the driver control the vehicle.
These modules may store data to
help your dealer/retailer technician
service your vehicle. Some modules
may also store data about how you
operate the vehicle, such as rate of
fuel consumption or average speed.
These modules may also retain the
owner’s personal preferences, such
as radio pre-sets, seat positions, and
temperature settings.
Customer Information 11-15
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