brake SATURN ION 2004 Repair Manual

Fuses Usage
FUEL PUMP Fuel Pump Relay
HVAC Climate Control
CLUSTER Instrument Panel Cluster
LIGHTER Cigar Lighter
RADIO
(BATT1)Radio Receiver, Entertainment
Memory
RADIO (ACC) Radio Receiver, Entertainment
SUNROOF Power Sunroof, OnStar Mirror
WIPER SWWindshield Wipers and Washers,
Transaxle Shift Lock Control Switch
DASH Instrument Panel, Dimming Switch
IGN SW Ignition Switch
PARK Headlamp Switch
PWR OUTLET Auxiliary Power OutletFuses Usage
PWR
WINDOWSPower Window Switches
STOP Stoplamp (Brake) Switch
BCM ELECTIgnition Switch, Body Control
Module (BCM)
BMC (PWR) Entry Control, Trunk Release
Relay Usage
RUNClimate Control (HVAC Blower,
Control Heads)
ACCPower Windows, Sunroof, Radio,
Wiper/Washer Switch, Accessory
Power Outlet
FUEL PUMP Fuel Pump
ALC/PARKOnStar, Radio, Instrument Panel
Cluster, Body Control Module
(Entry Control), Cigar Lighter,
Headlamp Switch, License Lamp
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Engine Compartment Fuse Block
(2.2L L4 Engine)
Some fuses are in a fuse block in the engine
compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Fuses Usage
1 ECM/TCMEngine Control Module,
Transmission Control Module
4 HDLP-RH Passenger’s Side Headlamp
5 A/C Air Conditioning Clutch Relay
8 ABS2Anti-Lock Brake System,
Traction Control Module
9 ECM Engine Control Module
10 ERLSCanister Purge Solenoid, Canister
Vent Solenoid, Low Coolant
Switch, Oxygen Sensors
11 IGNElectric Ignition Control Module,
Charging System, Neutral Stop
Back-Up Switch
13 TRANS2 Transaxle (VTi Variable)
14 TRANS1Transmission Control Module,
Neutral Stop Back-Up
15 BACK-UP PRNDIL, Back-up Switch
16 INJECTORS Fuel Injectors (Cylinder 1, 2, 3, 4)
17 FOG Fog Lamp Micro Relay
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Fuses Usage
18 HDLP-LH Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 PREM AUDIOEntertainment, Premium Radio
Amplier
22 ABSAnti-Lock Brake System,
Traction Control Module
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABSAnti-Lock Brake System,
Traction Control Module
41 IP BATT2 Body Control Module
42 EPS2 Electric Power Steering
43 EPS1 Electric Power Steering
45 COOLING
FANCooling Fan Mini Relay
46 CRANKPowertrain Control Module
Mini RelayFuses Usage
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control Module
Relays Usage
24 A/C Air Conditioning Clutch
25 HORN Horn
26 FOG LAMP Fog Lamps
28 RUN/CRANK Body Control Module
30 COOLING
FANEngine Cooling Fan
31 PCM CONT ECM
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
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Engine Compartment Fuse Block
(2.0L Supercharged Engine)
Some fuses are in a fuse block in the engine
compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Fuses Usage
1 ECM Engine Control Module
4 RH HDLP Passenger’s Side Headlamp
5 A/C Air Conditioning Clutch Relay
8 ABS Anti-Lock Brake System
9 ECM/ETC Engine Control Module
10 EMISSCanister Purge Solenoid, Mass Air
Flow Sensor, Low Coolant Switch,
Oxygen Sensors
11 IGN Ignition Coils (1,2,3,4)
13 ECM Engine Control Module
14 BOOST Engine Boost Solenoid
15 BACK-UP Back-up Switch
16 INJECTORS Fuel Injectors (Cylinder 1, 2, 3, 4)
18 LH HDLP Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 RADIO Radio
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Fuses Usage
22 ABS Anti-Lock Brake System
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABS Anti-Lock Brake System
41 IP BATT2 Body Control Module
43 EPS Electric Power Steering
44 COOLING
FAN 2Cooling Fan Mini Relay
45 COOLING
FAN 1Cooling Fan Mini Relay
46 CRANK Crank
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control ModuleRelays Usage
24 A/C CLUTCH Air Conditioning Clutch
25 HORN Horn
27 AFTER
COOLER PUMPAfter Cooler Pump
28 RUN/CRANK Body Control Module
29 POWERTRAINPowertrain
30 COOLING
FAN 1Engine Cooling Fan
31 ECM CONT Starter Solenoid
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. Reset oil life system. SeeEngine Oil on
page 5-15.An Emission Control Service.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-22.An Emission Control Service. See footnote †.••
Rotate tires and check ination pressures and wear. SeeTires on page 5-58.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels and add uid as
needed.••
Perform any needed additional services. See “Additional Required Services” in
this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
Replace passenger compartment air lter.See footnote (k).•
Inspect throttle system.See footnote (g).•
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Maintenance Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(a)Visually inspect brake lines and hoses for proper
hook-up, binding, leaks, cracks, chang, etc. Inspect
disc brake pads for wear and rotors for surface
condition. Inspect drum brake linings for wear or cracks.
Inspect other brake parts, including drums, wheel
cylinders, calipers, parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear.
(c)Visually inspect hoses and have them replaced if
they are cracked, swollen or deteriorated. Inspect
all pipes, ttings and clamps; replace with genuine
Saturn 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.(d)Visually inspect wiper blades for wear or cracking.
Replace blade inserts that appear worn or damaged
or that streak or miss areas of the windshield.
(e)Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages
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 doing its
job, have it repaired. Have any torn or frayed safety belts
replaced. Also look for any opened or broken air bag
coverings, and have them repaired or replaced. (The air
bag system does not need regular maintenance.)
(f)Lubricate all key lock cylinders, door hinges and
latches, hood hinges and latches, glove box hinges,
sunroof (if equipped) and any folding seat hardware.
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.
(g)Check system for interference or binding and
for damaged or missing parts. Replace parts as needed.
Replace any components that have high effort or
excessive wear. Do not lubricate accelerator or cruise
control cables.
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At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-30if
necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.3. On automatic transaxle vehicles, try to start the
engine in each gear. The starter should work
only in PARK (P) or NEUTRAL (N). If the starter
works in any other position, contact your Saturn
retailer for service.
On manual transaxle vehicles, put the shift lever in
Neutral (N), push the clutch pedal down halfway
and try to start the engine. The starter should work
only when the clutch pedal is pushed down all
the way to the oor. If the starter works when the
clutch is not pushed all the way down, contact your
Saturn retailer for service.
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Automatic Transaxle Shift Lock Control
System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-30if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the key to the RUN
position, but do not start the engine. Without
applying the regular brake, try to move the shift
lever out of PARK (P) with normal effort. If the shift
lever moves out of PARK (P), contact your
Saturn retailer for service.
Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to OFF in each shift lever position.
With an automatic transaxle, the key should turn to
OFF only when the shift lever is in PARK (P). The
key should come out only in OFF.
With a manual transaxle, the key should come out
only in OFF.
Contact your Saturn retailer if service is required.
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Parking Brake and Automatic Transaxle
Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
To check the parking brake’s holding ability: With
the engine running and transaxle in NEUTRAL (N),
slowly remove foot pressure from the regular
brake pedal. Do this until the vehicle is held by the
parking brake only.
To check the PARK (P) mechanism’s holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Contact your Saturn retailer if service is required.
Underbody Flushing Service
At least every spring, use plain water to ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
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