service SATURN ION 2004 Service Manual

After changing the engine oil, reset the system by doing
the following:
1. Press and release the trip/reset button until the
OIL LIFE message is displayed.
2. Then press and hold the trip/reset button until a
chime sounds ve times, and RESET is displayed
in the message center.
When the system is reset, the odometer will again
be displayed in the message center.
3. Turn the key to LOCK.
If the CHG OIL message comes back on when you start
your vehicle, the engine oil life system has not reset.
Repeat the procedure.
Your vehicle has a unique oil lter element. When
installing the ller cap do not exceed 18 lb-ft (25Y).
Inspect the condition of the O-ring and replace if
damaged. See your Saturn retailer for additional
information.What to Do with Used Oil
Used engine oil contains certain elements that may 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. Instead, recycle it by
taking it to a place that collects used oil. If you have
a problem properly disposing of your used oil, ask your
retailer, a service station or a local recycling center
for help.
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3. Pull the air cleaner/lter box cover out and remove
the air lter element from the air lter box. If the
element is dirty, you should replace it. If the element
is only dusty, it may be cleaned by blowing
compressed air through it from the clean side.
Make sure you are away from your engine
compartment when cleaning the air lter with
compressed air.
4. Wipe all dust from inside the housing and inspect the
air cleaner and air inlet tube for cracks, cuts and
deterioration. The air inlet tube must be replaced if it
is damaged.
5. Install the air lter element, hose, hose clamp and
cover.
6. For vehicles equipped with the 2.2L engine, latch
the two clips. For vehicles equipped with the 2.0L
supercharged engine, replace the three screws.Automatic Transaxle Fluid
It is not necessary to check the transaxle uid level.
A transaxle uid leak is the only reason for uid loss.
If a leak occurs, take the vehicle to retailer’s service
department and have it repaired as soon as possible.
You may also have your uid level checked by your
retailer or service center when you have your oil
changed.
Change both the uid and lter every 50,000 miles
(83 000 km) 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.
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If you do not use your vehicle under any of these
conditions, the uid and lter do not require changing.
Notice:For VTi variable transaxles, use only Saturn
Variable Transaxle Fluid. Using any other uid will
result in transaxle damage. Damage cause by
the use of uid other than Saturn Variable Transaxle
Fluid will not be covered by your warranty.
Notice:For ve-speed automatic transaxles,
use only Saturn T-IV Transaxle Fluid. Using any
other uid will result in transaxle damage. Damage
cause by the use of uid other than Saturn T-IV
Transaxle Fluid will not be covered by your
warranty.Manual Transaxle Fluid
It is not necessary to check the transaxle uid level.
A transaxle uid leak is the only reason for uid loss.
If a leak occurs, take the vehicle to your retailer’s service
department and have it repaired as soon as possible.
You may also have your uid level checked by your
retailer or service center when you have your oil
changed. SeeRecommended Fluids and Lubricants
on page 6-14for the proper uid to use.
Hydraulic Clutch
The hydraulic clutch linkage in your vehicle is
self-adjusting. This system does not have its own
reservoir. It receives uid from the brake master
cylinder reservoir.
SeeBrakes on page 5-38for more information.
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If No Steam Is Coming From Your
Engine
An overheat warning can indicate a serious problem.
SeeLow Coolant Level Warning Message on page 3-43.
If you get an engine overheat warning with no warning
messages, but see or hear no steam, the problem
may not be too serious. Sometimes the engine can get
a little too hot when you:
Climb a long hill on a hot day.
Stop after high-speed driving.
Idle for long periods in traffic.
Tow a trailer.
If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. If you have an air conditioner and it’s on, turn it off.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
3. Try to minimize engine load. If you’re in a traffic
jam, shift to NEUTRAL (N); otherwise, shift to the
highest gear while driving.If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn’t come back on, you can drive
normally.
If the warning continues and you have not stopped,
pull over, stop, and park your vehicle right away.
If there’s still no sign of steam, you can idle the engine
for three minutes while you’re parked. If you still
have the warning,turn off the engine and get everyone
out of the vehicleuntil it cools down.
You may decide not to lift the hood but to get service
help right away.
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The coolant level should be at the cold ll line. If it isn’t,
you may have a leak at the radiator hoses, heater
hoses, radiator, water pump or somewhere else in the
cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
CAUTION: (Continued)
CAUTION: (Continued)
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.
If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fans are running.
If the engine is overheating, both fan should be running.
If it isn’t, your vehicle needs service. Turn off the
engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
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Brake Wear
Your vehicle has front disc brakes and rear drum brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving (except when you are pushing on the
brake pedal rmly).
{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to Saturn specications.
The rear drum brakes do not have wear indicators,
but if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. Also, the
rear brake drums should be removed and inspected
each time the tires are removed for rotation or changing.
When you have the front brake pads replaced, have
the rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.Brake Pedal Travel
See your retailer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your brakes
adjust for wear. If you rarely make a moderate or heavier
stop, then your brakes might not adjust correctly. If you
drive in that way, then — very carefully — make a few
moderate brake stops about every 1,000 miles
(1 600 km), so your brakes will adjust properly.
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10. Now start the vehicle with the good battery and run
the engine for a while.
11. Press UNLOCK on the RKE transmitter to disarm
your security system (if equipped).
12. Try to start the vehicle that had the dead battery.
If it won’t start after a few tries, it probably needs
service.
Notice:If the jumper cables are removed in the
wrong order, electrical shorting may occur and
damage the vehicle. The repairs would not be
covered by your warranty. 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
B. Good Battery
C. Dead BatteryJumper Cable Removal
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To 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 terminal cover to its original position.Headlamp Aiming
Headlamp aim has been preset at the factory and
should need no further adjustment.
If your vehicle is damaged in an accident, the headlamp
aim may be affected. Aim adjustment to the low beam
may be necessary if it is difficult to see lane markers
(for horizontal aim), or if oncoming drivers ash
their high beams at you (for vertical aim). If you believe
your headlamps need to be re-aimed, we recommend
that you take your vehicle to your retailer for service.
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Tires
Your new vehicle comes with high-quality tires made by
a leading tire manufacturer. If you ever have questions
about your tire warranty and where to obtain service,
see your GM Warranty booklet for details. For additional
information refer to the tire manufacturer’s booklet
included with your vehicle’s Owner’s Manual.
{CAUTION:
Poorly maintained and improperly used tires
are dangerous.
Overloading your tires can cause
overheating as a result of too much
friction. You could have an air-out and a
serious accident. See “Loading Your
Vehicle” in the Index.
CAUTION: (Continued)
CAUTION: (Continued)

Underinated tires pose the same danger
as overloaded tires. The resulting accident
could cause serious injury. Check all tires
frequently to maintain the recommended
pressure. Tire pressure should be checked
when your tires are cold.
Overinated tires are more likely to be
cut, punctured or broken by a sudden
impact — such as when you hit a pothole.
Keep tires at the recommended pressure.
Worn, old tires can cause accidents.
If your tread is badly worn, or if your tires
have been damaged, replace them.
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Tire Sidewall Labeling
Useful information about a tire is molded into its
sidewall.
(A) Tire Size:The tire size code is a combination of
letters and numbers used to dene a particular
tire’s width, height, aspect ratio, construction type and
service description. See the “Tire Size” illustration
later in this section for more detail.
(B) Tire Performance Criteria Specication
(TPC Spec):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.
(C) Department of Transportation (DOT):The
Department of Transportation (DOT) code indicates that
the tire is in compliance with the U.S. Department of
Transportation Motor Vehicle Safety Standards.
(D) Tire Identication Number (TIN):The letters and
numbers following DOT code are the Tire Identication
Number (TIN). The TIN shows the manufacturer and
plant code, tire size, and date the tire was manufactured.
The TIN is molded onto both sides of the tire, although
only one side may have the date of manufacture.
(E) Tire Ply Material:The type of cord and number of
plies in the sidewall and under the tread.
(F) Uniform Tire Quality Grading (UTQG):Tire
manufacturers are required to grade tires based on three
performance factors: treadwear, traction and temperature
resistance. For more information seeUniform Tire Quality
Grading on page 5-71.
(G) Maximum Cold Ination Load Limit:Maximum
load that can be carried and the maximum pressure
needed to support that load. For more information on
recommended tire pressure seeInation - Tire Pressure
on page 5-66andLoading Your Vehicle on page 4-33. Passenger Car Tire Example
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