Engine SATURN ASTRA 2009 Manual PDF

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 the
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 the vehicle’s
engine code.
Service Parts
Identication Label
This label is on the trunk oor. It is
very helpful if parts need to be
ordered. 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
10-2 Technical Data
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ApplicationCapacities
English Metric
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.
Engine Specications
Engine VIN CodeTransmission Spark Plug Gap
1.8L L4 1Automatic
Manual 0.035 in (0.90 mm)
Technical Data 10-3
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Service and
Maintenance
Service and Maintenance
Introduction.......................11-1
Maintenance
Requirements..................11-1
Your Vehicle and the
Environment....................11-2
Using the Maintenance
Schedule.........................11-2
Scheduled Maintenance. . . .11-3
Additional Required
Services..........................11-6
Maintenance Footnotes.....11-8
Owner Checks and
Services..........................11-9
At Each Fuel Fill...............11-9
At Least Once a Month. . .11-10
At Least Once a Year.....11-10
Recommended Fluids
and Lubricants...............11-12
Maintenance
Replacement Parts........11-14
Engine Drive Belt
Routing..........................11-15
Maintenance Record........11-16
Service and
Maintenance
Introduction
Important: Keep engine oil at
the proper level and change as
recommended.
Maintenance
Requirements
Notice:Maintenance intervals,
checks, inspections, replacement
parts, and recommended uids
and lubricants as prescribed
in this manual are necessary to
keep this vehicle in good working
condition. Any damage caused
by failure to follow scheduled
maintenance might not be
covered by the vehicle warranty.
Service and Maintenance 11-1
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{CAUTION
Performing maintenance work on
a vehicle can be dangerous.
In trying to do some jobs, you can
be seriously injured. Do your own
maintenance work only if you
have the required know-how and
the proper tools and equipment
for the job. If you have any doubt,
see your dealer/retailer to have a
qualied technician do the work.
SeeDoing Your Own Service
Work on page 9-4.
Some maintenance services can be
complex. So, unless you are
technically qualied and have the
necessary equipment, have
your dealer/retailer do these jobs.
When you go to your dealer/retailer
for service, trained and supported
service technicians will perform
the work using genuine parts.To purchase service information,
seeService Publications Ordering
Information on page 12-15.
Owner Checks and Services on
page 11-9tells what should
be checked, when to check it, and
what can easily be done to help
keep the vehicle in good condition.
The proper replacement parts,
uids, and lubricants to use
are listed inRecommended Fluids
and Lubricants on page 11-12
andMaintenance Replacement
Parts on page 11-14. When
the vehicle is serviced, make sure
these are used. All parts should
be replaced and all necessary
repairs done before you or anyone
else drives the vehicle. We
recommend the use of genuine
parts from your dealer/retailer.
Scheduled Maintenance
When the letters InSP appear in
the odometer display, service
is required for the vehicle. Have the
vehicle serviced as soon as
possible within the mileage indicated
on the display. 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 technicians
who will perform this work using
genuine parts and reset the system.
If the engine oil life system is
ever reset accidentally, service
the vehicle within 3,000 miles
(5 000 km) since the last service.
Remember to reset the oil life
system whenever the oil is changed.
SeeEngine Oil Life System on
page 9-9for information on the oil
life system and resetting the system.
Service and Maintenance 11-3
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When InSP appears, certain
services, checks, and inspections
are required. Required services
are described in the following
for “MaintenanceI” and
“Maintenance II.” Generally, it is
recommended that the rst service
be Maintenance I, the second
service be Maintenance II, and then
alternate Maintenance Iand Maintenance
IIthereafter. However,
in some cases, Maintenance II
might be required more often.
Maintenance I—Use
Maintenance Iif InSP displays
within 10 months since the vehicle
was purchased or Maintenance II
was performed. Maintenance
II—Use
Maintenance IIif the previous
service performed was
Maintenance I. Always use
Maintenance IIwhenever the letters
InSP display 10 months or more
since the last service or if InSP has
not come on at all for one year.
Scheduled Maintenance
Service MaintenanceIMaintenance II
Change engine oil and lter. See Engine Oil on page 9-7. Reset oil life system.
See Engine Oil Life System on page 9-9 .An Emission Control Service. ••
Visually check for any leaks or damage. See footnote (a). ••
Inspect engine air cleaner lter. If necessary, replace lter. See Engine Air
Cleaner/Filter on page 9-11 .See footnote (b). •
Rotate tires and check ination pressures and wear. See Tire Inspection and
Rotation on page 9-52 and “Tire Wear Inspection” in At Least Once a Month
on page 11-10. ••
11-4 Service and Maintenance
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Scheduled Maintenance (cont’d)
ServiceMaintenanceIMaintenance II
Inspect brake system. See footnote (c). ••
Check engine coolant and windshield washer uid levels and add uid as
needed. ••
Perform any needed additional services. See Additional Required Services
on page 11-6. ••
Inspect suspension and steering components. See footnote (d). •
Inspect engine cooling system. See footnote (e). •
Inspect wiper blades. See footnote (f). •
Inspect restraint system components. See footnote (g). •
Lubricate body components. See footnote (h). •
Service and Maintenance 11-5
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Additional Required Services
The following services should be performed at the rst maintenance service (Ior II) after the indicated miles
(kilometers) shown for each item.
Additional Required Services
Service and Miles (Kilometers) 25,000
(40 000) 50,000
(80 000) 75,000
(120 000) 100,000
(160 000) 125,000
(200 000) 150,000
(240 000)
Inspect fuel system for damage or leaks. ••• • • •
Inspect exhaust system for loose or
damaged components. ••• • • •
Replace engine air cleaner lter.
See Engine Air Cleaner/Filter on
page 9-11. •• •
Replace passenger compartment
air lter. ••• • • •
Change automatic transmission uid
(severe service). See footnote (i). •• •
Change automatic transmission uid
(normal service). •
Replace spark plugs.
An Emission Control Service.
Not to exceed 35,000 miles (56 000 km). ••• • • •
11-6 Service and Maintenance
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Additional Required Services (cont’d)
Service and Miles (Kilometers)25,000
(40 000) 50,000
(80 000) 75,000
(120 000) 100,000
(160 000) 125,000
(200 000) 150,000
(240 000)
Engine cooling system service (or every
ve years, whichever occurs rst).
An Emission Control Service.
See footnote (j). •
Solid lifter tappet adjustment (or every
10 years, whichever occurs rst).
See footnote (m).
Not to exceed 90,000 miles (144 000 km). ••
Replace timing belt and tensioner
(or every 10 years, whichever
occurs rst). See footnote (m).
Not to exceed 100,000 miles (160 000 km). ••
Inspect engine accessory drive belt
(or every two years, whichever occurs
rst). An Emission Control Service.
See footnote (k).
Not to exceed 36,000 miles (58 000 km). ••• • • •
Change brake and clutch hydraulic uid at
a regular maintenance service every
two years. See footnote (l).
Service and Maintenance 11-7
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Maintenance Footnotes
(a)A fluid loss in any vehicle system
could indicate a problem. Have the
system inspected and repaired
and the fluid level checked. Add fluid
if needed.
(b)If driving regularly under dusty
conditions or in high-polluted
regions, replace the filter at each
engine oil change.
(c)Inspect brake lines and hoses for
proper hook-up, binding, leaks,
cracks, chafing, etc. Inspect disc
brake pads for wear and rotors for
surface condition. Inspect other
brake parts, including calipers,
parking brake, etc.
(d)Inspect front and rear suspension
and steering system for damaged,
loose, or missing parts or signs of
wear. Inspect power steering cables
for proper hook-up, binding, cracks,
chafing, etc. Inspect power steering
hydraulic lines and hoses for proper
hook-up, binding, leaks, cracks,
chafing, etc.(e)Inspect hoses and have them
replaced if they are cracked,
swollen, or deteriorated. Inspect all
pipes, fittings and clamps; replace
with genuine parts as needed.
To help ensure proper operation,
a pressure test of the cooling system
and pressure cap and cleaning
the outside of the radiator and
air conditioning condenser is
recommended at least once a year.
(f)Inspect wiper blades for wear,
cracking, or contamination.
Clean the windshield and wiper
blades, if contaminated. Replace
wiper blades that are worn or
damaged. See Windshield Wiper
Blade Replacement on page 9-21
and “Windshield and Wiper Blades”
in Exterior Cleaning on page 9-76.
(g)Make sure the safety belt
reminder light and safety belt
assemblies are working properly.
Look for any other loose or
damaged safety belt system parts.
If you see anything that might keep
a safety belt system from doingits job, have it repaired. Have any
torn or frayed safety belts replaced.
Also see Airbag System Check
on page 1-37.
(h)Lubricate all key lock cylinders,
door hinges and latches, hood
hinges and latches, and trunk lid
hinges and latches. More frequent
lubrication may be required
when exposed to a corrosive
environment. Applying silicone
grease on weatherstrips with a clean
cloth will make them last longer,
seal better, and not stick or squeak.
(i)Change automatic transmission
fluid if the vehicle is mainly driven
under one or more of these
conditions:
In heavy city traffic where the
outside temperature regularly
reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer
towing.
Uses such as found in taxi, police,
or delivery service.
11-8 Service and Maintenance
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