engine SATURN ASTRA 2009 Service Manual

Filling the Tank
{CAUTION
Fuel vapor burns violently and a
fuel re can cause bad injuries.
To help avoid injuries to you and
others, read and follow all the
instructions on the pump island.
Turn off the engine when you are
refueling. Do not smoke if you are
near fuel or refueling the vehicle.
Do not use cellular phones. Keep
sparks, ames, and smoking
materials away from fuel. Do not
leave the fuel pump unattended
when refueling the vehicle. This is
against the law in some places.
Do not re-enter the vehicle while
pumping fuel. Keep children away
from the fuel pump; never let
children pump fuel.The fuel cap is located behind a
hinged fuel door on the passenger
side of the vehicle.
To remove the fuel cap, turn it
slowly counterclockwise.
The fuel cap has a spring in it, if the
cap is released too soon it will
spring back.
{CAUTION
Fuel can spray out on you if you
open the fuel cap too quickly. If
you spill fuel and then something
ignites it, you could be badly
burned. This spray can happen if
the tank is nearly full, and is more
likely in hot weather. Open the
fuel cap slowly and wait for any
hiss noise to stop. Then unscrew
the cap all the way.
Be careful not to spill fuel. Do not top
off or overll the tank and wait a few
seconds after you have nished
pumping before removing the nozzle.
Clean fuel from painted surfaces as
soon as possible. SeeExterior
Cleaning on page 9-76.
When replacing the fuel cap, turn
it clockwise until it clicks. Make
sure the cap is fully installed.
The diagnostic system can
determine if the fuel cap has been
left off or improperly installed.
8-36 Driving and Operating
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Vehicle Service
and Care
Service
Service...............................9-2
Accessories and
Modications.....................9-3
California Proposition 65
Warning............................9-3
California Perchlorate
Materials Requirements.....9-3
Doing Your Own
Service Work....................9-4
Adding Equipment to the
Outside of the Vehicle......9-4
Owner Checks
Owner Checks....................9-4
Hood Release.....................9-5
Engine Compartment
Overview...........................9-6
Engine Oil..........................9-7
Engine Oil Life System.......9-9
Engine Air Cleaner/Filter. . .9-11
Automatic Transmission
Fluid................................9-12
Manual Transmission
Fluid................................9-12
Hydraulic Clutch................9-12
Cooling System.................9-12
Engine Coolant.................9-16
Pressure Cap....................9-18
Engine Overheating...........9-18
Power Steering Fluid.........9-20
Windshield Washer
Fluid................................9-20
Windshield Wiper Blade
Replacement...................9-21
Brakes..............................9-22
Battery..............................9-25
Headlamp Aiming
Headlamp Aiming..............9-26
Bulb Replacement
Bulb Replacement.............9-28
Halogen Bulbs..................9-28
Front Turn Signal
Lamps.............................9-28
Center High-Mounted
Stoplamp (CHMSL).........9-29
Taillamps (Five-Door
Hatchback)......................9-30
Taillamps (Three-Door
Hatchback)......................9-32
License Plate Lamp..........9-33
Replacement Bulbs...........9-34
Electrical System
Add-On Electrical
Equipment.......................9-34
Headlamp Wiring..............9-34
Fuses...............................9-35
Engine Compartment
Fuse Block......................9-35
Rear Compartment Fuse
Block...............................9-37
Tires
Tires.................................9-40
Winter Tires......................9-41
Tire Sidewall Labeling.......9-42
Tire Terminology and
Denitions.......................9-44
Ination - Tire Pressure. . . .9-47
High-Speed Operation.......9-48
Tire Pressure Monitor
System............................9-49
Tire Pressure Monitor
Operation........................9-51
Tire Inspection and
Rotation..........................9-52
Vehicle Service and Care 9-1
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Accessories and
Modications
When non-dealer/non-retailer
accessories are added to the
vehicle, they can affect vehicle
performance and safety, including
such things as airbags, braking,
stability, ride and handling,
emissions systems, aerodynamics,
durability, and electronic systems
like antilock brakes, traction control,
and stability control. Some of
these accessories could even cause
malfunction or damage not
covered by the vehicle warranty.
Damage to vehicle components
resulting from the installation or use
of non-GM certied parts, including
control module modications,
are not covered under the terms of
the vehicle warranty and may
affect remaining warranty coverage
for affected parts.GM Accessories are designed to
complement and function with other
systems on the vehicle. Your GM
dealer/retailer can accessorize
the vehicle using genuine GM
Accessories. When you go to your
GM dealer/retailer and ask for
GM Accessories, you will know that
GM-trained and supported service
technicians will perform the work
using genuine GM Accessories.
Also, seeAdding Equipment to
Your Airbag-Equipped Vehicle on
page 1-36.
California Proposition 65
Warning
Most motor vehicles, including this
one, contain and/or emit chemicals
known to the State of California
to cause cancer and birth defects
or other reproductive harm.Engine exhaust, many parts and
systems (including some inside the
vehicle), many uids, and some
component wear by-products
contain and/or emit these chemicals.
California Perchlorate
Materials Requirements
Certain types of automotive
applications, such as airbag
initiators, seat belt pretensioners,
and lithium batteries contained
in remote keyless transmitters,
may contain perchlorate materials.
Special handling may be necessary.
For additional information, see
www.dtsc.ca.gov/hazardouswaste/
perchlorate.
Vehicle Service and Care 9-3
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Doing Your Own
Service Work
{CAUTION
You can be injured and the vehicle
could be damaged if you try to do
service work on a vehicle without
knowing enough about it.
Be sure you have sufficient
knowledge, experience, the
proper replacement parts, and
tools before attempting any
vehicle maintenance task.
Be sure to use the proper
nuts, bolts, and other
fasteners. English and metric
fasteners can be easily
confused. If the wrong
fasteners are used, parts
can later break or fall off.
You could be hurt.
If doing some of your own service
work, use the proper service
manual. It tells you much moreabout how to service the vehicle
than this manual can. To order the
proper service manual, see
Service Publications Ordering
Information on page 12-15.
This vehicle has an airbag system.
Before attempting to do your
own service work, seeAirbag
System Check on page 1-37.
Keep a record with all parts receipts
and list the mileage and the date
of any service work performed. See
Maintenance Record on page 11-16.Adding Equipment to
the Outside of the
Vehicle
Things added to the outside of the
vehicle can affect the airow
around it. This can cause wind
noise and can affect fuel economy
and windshield washer performance.
Check with your dealer/retailer
before adding equipment to
the outside of the vehicle.
Owner Checks
{CAUTION
An electric fan under the hood can
start up and injure you even when
the engine is not running. Keep
hands, clothing, and tools away
from any underhood electric fan.
{CAUTION
Things that burn can get on hot
engine parts and start a re.
These include liquids like fuel, oil,
coolant, brake uid, windshield
washer and other uids, and
plastic or rubber. You or others
could be burned. Be careful not to
drop or spill things that will burn
onto a hot engine.
9-4 Vehicle Service and Care
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Engine Compartment Overview
When you open the hood, this is what you will see:
9-6 Vehicle Service and Care
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A.Engine Air Cleaner/Filter on
page 9-11.
B. Engine Oil Fill Cap.Engine Oil
on page 9-7.
C. Brake Fluid Reservoir.Brakes
on page 9-22.
D. Coolant Reservoir.Cooling
System on page 9-12.
E. Coolant Reservoir Pressure Cap.
Pressure Cap on page 9-18.
F.Engine Compartment Fuse Block
on page 9-35.
G.Battery on page 9-25.
H.Windshield Washer Fluid on
page 9-20.
I. Engine Oil Dipstick.Engine Oil
on page 9-7.Engine Oil
If the low oil level light appears on
the instrument cluster, check the
engine oil level right away. SeeLow
Oil Level Light on page 4-22.
Check the engine oil level regularly;
this is just a reminder.
Checking Engine Oil
It is a good idea to check the
engine oil level at each fuel ll.
In order to get an accurate reading,
the oil must be warm and the
vehicle must be on level ground.The engine oil dipstick handle
is a yellow loop. SeeEngine
Compartment Overview on page 9-6
for the location of the engine oil
dipstick.
1. Turn off the engine and give the
oil several minutes to drain back
into the oil pan. If this is not
done, the oil dipstick might not
show the actual level.
2. Pull the dipstick and clean it with
a paper towel or cloth, then push
it back in all the way. Remove
it again, keeping the tip down and
check the level.
Vehicle Service and Care 9-7
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When to Add Engine Oil
If the oil is below the MIN (minimum)
mark, add at least one quart/liter of
the recommended oil. This section
explains what kind of oil to use.
For engine oil crankcase capacity,
seeCapacities and Specifications
on page 10-2.
Notice:Do not add too much oil.
If the engine has so much oil
that the oil level gets above the
upper mark that shows the proper
operating range, the engine
could be damaged.
SeeEngine Compartment Overview
on page 9-6for the location of the
engine oil ll cap.
Add enough oil to put the level
somewhere in the proper operating
range. Push the dipstick all the
way back in when through.
What Kind of Engine Oil to Use
Look for three things:
GM6094M
Use only an oil that meets
GM Standard GM6094M.
SAE 5W-30
SAE 5W-30 is best for the
vehicle. These numbers on an
oil container show its viscosity,
or thickness. Do not use other
viscosity oils such as
SAE 20W-50.
American Petroleum Institute
(API) starburst symbol
Oils meeting these requirements
should have the starburst symbol
on the container. This symbol
indicates that the oil has been
certied by the American
Petroleum Institute (API).
9-8 Vehicle Service and Care
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Notice:Use only engine oil
identied as meeting GM Standard
GM6094M and showing the
American Petroleum Institute
Certied For Gasoline Engines
starburst symbol. Failure to use
the recommended oil can result
in engine damage not covered by
the vehicle warranty.
Cold Temperature Operation
If in an area of extreme cold, where
the temperature falls below−20°F
(−29°C), use either an SAE 5W-30
synthetic oil or an SAE 0W-30
engine oil. Both provide easier cold
starting for the engine at extremely
low temperatures. Always use
an oil that meets the required
specication, GM6094M.
See “What Kind of Engine Oil to
Use” for more information.
Engine Oil Additives / Engine
Oil Flushes
Do not add anything to the oil.
The recommended oils with
the starburst symbol that meet
GM Standard GM6094M are all that
is needed for good performance
and engine protection.
Engine oil system ushes are not
recommended and could cause
engine damage not covered by the
vehicle warranty.
Engine Oil Life System
When to Change Engine Oil
This vehicle has a computer system
that indicates when to change the
engine oil and lter. This is based on
engine revolutions and engine
temperature, and not on mileage.
Based on driving conditions,
the mileage at which an oil change
is indicated can vary considerably.
For the oil life system to work
properly, the system must be reset
every time the oil is changed.When the system has calculated
that oil life has been diminished,
it indicates that an oil change
is necessary. The letters InSP will
appear in the odometer display.
Change the oil as soon as possible
within the mileage indicated on
the display. If driving under the
best conditions, the oil life system
might indicate that an oil change
is necessary once a year.
The engine oil and lter must be
changed at least once a year and
at this time the system must be
reset. Your dealer/retailer has
trained service people who will
perform this work using genuine
parts and reset the system. It is also
important to check the oil regularly
and keep it at the proper level.
If the system is ever reset
accidentally, the oil must be
changed at 3,000 miles (5 000 km)
since the last oil change.
Remember to reset the oil life
system whenever the oil is changed.
Vehicle Service and Care 9-9
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How to Reset the Engine Oil
Life System
The Engine Oil Life System
calculates when to change the
engine oil and lter based on vehicle
use. Whenever the oil is changed,
reset the system so it can calculate
when the next oil change is required.
If a situation occurs where the oil is
changed prior to the letters InSP
appearing in the odometer display,
reset the system.
After changing the engine oil, reset
the system:
1. Turn the ignition key to
LOCK/OFF.
2. Press the instrument panel
cluster stem until the odometer is
displayed, then release the stem.3. Re-press and hold the cluster
stem until the letters InSP are
displayed.
4. Press and hold the brake pedal
down, hold the cluster stem
down, and turn the ignition key
to ON/RUN.
5. The letters InSP in the instrument
panel cluster display will ash.
6. Keep the cluster stem down for
at least 10 seconds and release
the stem and the brake pedal
when the message “new
remaining milage” is displayed.
What to Do with Used Oil
Used engine oil contains certain
elements that can be unhealthy for
your skin and could even cause
cancer. Do not let used oil stay on
your skin for very long. Clean your
skin and nails with soap and water,
or a good hand cleaner. Wash or
properly dispose of clothing or rags
containing used engine oil. See the
manufacturer’s warnings about the
use and disposal of oil products.
Used oil can be a threat to the
environment. If you change your own
oil, be sure to drain all the oil from the
lter before disposal. Never dispose
of oil by putting it in the trash, pouring
it on the ground, into sewers, or into
streams or bodies of water. Recycle
it by taking it to a place that collects
used oil.
9-10 Vehicle Service and Care
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Engine Air Cleaner/Filter
SeeEngine Compartment Overview
on page 9-6for the location of
the engine air cleaner/lter.
When to Inspect the Engine
Air Cleaner/Filter
Inspect the air cleaner/lter at the
MaintenanceIIintervals and replace
it at the rst oil change after each
50,000 mile (83 000 km) interval.
See “Schedule Maintenance”
in Service and Maintenance formore information. If you are driving
in dusty/dirty conditions, inspect
the lter at each engine oil change.
How to Inspect the Engine
Air Cleaner/Filter
To inspect the air cleaner/lter,
remove the lter from the vehicle
and lightly shake the lter to release
loose dust and dirt. If the lter
remains caked with dirt, a new lter
is required.
To inspect or replace the engine air
cleaner/lter.
1. Remove the screws that hold the
cover on.
2. Disconnect the electrical
connector.
3. Lift off the cover.
4. Inspect or replace the engine air
cleaner/lter.
5. Reverse Steps 1 through 3 to
reinstall the cover and reconnect
the electrical connector.
{CAUTION
Operating the engine with the air
cleaner/lter off can cause you
or others to be burned. The air
cleaner not only cleans the air; it
helps to stop ames if the engine
backres. If it is not there and the
engine backres, you could be
burned. Do not drive with it off, and
be careful working on the engine
with the air cleaner/lter off.
Notice:If the air cleaner/lter
is off, a backre can cause
a damaging engine re. And, dirt
can easily get into the engine,
which will damage it. Always have
the air cleaner/lter in place when
you are driving.
Vehicle Service and Care 9-11
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