engine SATURN ASTRA 2009 Repair Manual

What to Add
Use only new DOT-4 brake uid
from a sealed container. It is
recommended that the brake
hydraulic system be ushed and
relled with new DOT-4 uid
at a regular maintenance service
every two years. SeeAdditional
Required Services on page 11-6
andRecommended Fluids and
Lubricants on page 11-12.
Always clean the brake uid
reservoir cap and the area around
the cap before removing it.
This helps keep dirt from entering
the reservoir.
{CAUTION
With the wrong kind of uid in
the brake hydraulic system,
the brakes might not work well.
This could cause a crash.
Always use the proper brake uid.Notice:
Using the wrong uid can badly
damage brake hydraulic system
parts. For example, just a few
drops of mineral-based oil,
such as engine oil, in the brake
hydraulic system can damage
brake hydraulic system parts so
badly that they will have to be
replaced. Do not let someone
put in the wrong kind of uid.
If brake uid is spilled on the
vehicle’s painted surfaces, the
paint nish can be damaged.
Be careful not to spill brake
uid on the vehicle. If you do,
wash it off immediately. See
Exterior Cleaning on page 9-76.
Brake Wear
This vehicle has disc brakes.
Notice:Continuing to drive
with worn-out brake pads could
result in costly brake repair.
Front disc brake pads have built-in
brake pad wear indicators that
make a high-pitched warning sound
when the brake pads are worn
and new pads are needed.
The sound can come and go or be
heard all the time the vehicle is
moving, except when applying the
brake pedal rmly.
{CAUTION
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
an accident. When the brake wear
warning sound is heard, have the
vehicle serviced.
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Replacing Brake System Parts
The braking system on a vehicle
is complex. Its many parts have to
be of top quality and work well
together if the vehicle is to have
really good braking. The vehicle was
designed and tested with top-quality
brake parts. When parts of the
braking system are replaced — for
example, when the brake linings
wear down and new ones are
installed — be sure to get new
approved replacement parts. If this
is not done, the brakes might not
work properly. For example,
if someone puts in brake linings
that are wrong for the vehicle, the
balance between the front and
rear brakes can change — for the
worse. The braking performance
expected can change in many other
ways if the wrong replacement
brake parts are installed.
Battery
This vehicle has a maintenance free
battery. When it is time for a new
battery, see your dealer/retailer
for one that has the replacement
number shown on the original
battery’s label. SeeEngine
Compartment Overview on page 9-6
for battery location.
Warning:Battery posts, terminals,
and related accessories contain
lead and lead compounds,
chemicals known to the State of
California to cause cancer and
reproductive harm. Wash hands
after handling.
Vehicle Storage
{CAUTION
Batteries have acid that can burn
you and gas that can explode.
You can be badly hurt if you are
not careful. SeeJump Starting
on page 9-69for tips on
working around a battery without
getting hurt.
Infrequent Usage: If the vehicle is
driven infrequently, remove the
black, negative (−) cable from the
battery. This helps keep the battery
from running down.
Extended Storage: For extended
storage of the vehicle, remove
the black, negative (−) cable from
the battery or use a battery
trickle charger. This helps maintain
the charge of the battery over
an extended period of time.
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Fuses
The wiring circuits in the vehicle
are protected from short circuits by
fuses. This greatly reduces the
chance of damage caused by
electrical problems.
Look at the silver-colored band
inside the fuse. If the band is
broken or melted, replace the fuse.
Be sure to replace a bad fuse
with a new one of the identical size
and rating.
There are two fuse blocks in the
vehicle: one in the engine
compartment and one in the trunk.
There is a fuse puller located on
the rear compartment fuse block.
SeeRear Compartment Fuse Block
on page 9-37. It can be used to
easily remove fuses from the
fuse block.
Engine Compartment
Fuse Block
The engine compartment fuse block
is located in the front left side
of the engine compartment.
SeeEngine Compartment
Overview on page 9-6.
To open the fuse block cover,
insert a tool into the latch and turn.
Pull up on the cover to remove.
Notice:Spilling liquid on
any electrical components on
the vehicle may damage it.
Always keep the covers on
any electrical component.
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FusesUsage
1 Antilock Brake
System (ABS) Valves
2 ABS PumpFuses Usage
4 Climate Control
System (Ignition)
5 Engine Cooling Fan
(AT and AC only)Fuses
Usage
6 Engine Cooling Fan
7 Windshield & Liftgate
Glass Washer Motor
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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/Injectors
26ECM (Sensor and
Actuators)Fuses Usage
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.
Use the fuse puller, to remove and
replace fuses.
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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.
(D) Construction Code
:A letter
code is used to indicate the
type of ply construction in the
tire. The letter R means radial
ply construction; the letter D
means diagonal or bias ply
construction; and the letter B
means belted-bias ply
construction.
(E) Rim Diameter
:Diameter of
the wheel in inches.
(F) Service Description
:These characters represent the
load index and speed rating
of the tire. The load index
represents the load carry
capacity a tire is certied to
carry. The speed rating is the
maximum speed a tire is certied
to carry a load.
Tire Terminology and
Denitions
Air Pressure:The amount of
air inside the tire pressing
outward on each square inch
of the tire. Air pressure is
expressed in pounds per square
inch (psi) or kilopascal (kPa).
Accessory Weight
:This means
the combined weight of optional
accessories. Some examples
of optional accessories are,
automatic transmission, power
steering, power brakes, power
windows, power seats, and air
conditioning.
Aspect Ratio
:The relationship
of a tire’s height to its width.
Belt
:A rubber coated layer of
cords that is located between the
plies and the tread. Cords may
be made from steel or other
reinforcing materials.
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Changing a Flat Tire
If a tire goes at, avoid further tire
and wheel damage by driving slowly
to a level place. Turn on the hazard
warning ashers. SeeHazard
Warning Flashers on page 4-4.
{CAUTION
Changing a tire can be dangerous.
The vehicle can slip off the jack
and roll over or fall on you or other
people. You and they could be
badly injured or even killed.
(Continued)
CAUTION (Continued)
Find a level place to change
your tire. To help prevent the
vehicle from moving:
1. Set the parking brake rmly.
2. Put an automatic
transmission shift lever in
P (Park), or shift a manual
transmission to 1 (First) or
R (Reverse).
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 the vehicle has a at tire (B),
use the following example as a
guide to assist you in the placement
of wheel blocks (A).
A. Wheel Block
B. Flat Tire
The following information explains
how to use the jack and change
a tire.
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Notice:If you leave the radio or
other accessories on during
the jump starting procedure,
they could be damaged. The
repairs would not be covered by
the warranty. Always turn off
the radio and other accessories
when jump starting the vehicle.
3. Turn off the ignition on both
vehicles. Unplug unnecessary
accessories plugged into
the cigarette lighter or the
accessory power outlet. Turn off
the radio and all lamps that
are not needed. This will avoid
sparks and help save both
batteries. And it could save
the radio!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. SeeEngine
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.
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.
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{CAUTION
Fans or other moving engine
parts can injure you badly. Keep
your hands away from moving
parts once the engine is running.
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 tothe 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 the vehicle 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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