engine SATURN ION 2004 Manual Online

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.
5-33
ProCarManuals.com

How to Add Coolant to the Coolant
Surge Tank
If you haven’t found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level isn’t at the cold ll line, add a
50/50 mixture ofclean, drinkable waterand DEX-COOL
®
coolant at the coolant surge tank, but be sure the
cooling system, including the coolant surge tank
pressure cap, is cool before you do it. SeeEngine
Coolant on page 5-26for more information.
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the coolant
surge tank pressure cap — even a little — they
can come out at high speed. Never turn the
cap when the cooling system, including the
coolant surge tank pressure cap, is hot.
Wait for the cooling system and coolant surge
tank pressure cap to cool if you ever have to
turn the pressure cap.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will.
CAUTION: (Continued)
5-34
ProCarManuals.com

CAUTION: (Continued)
Your vehicle’s coolant warning system is set for
the proper coolant mixture. With plain water or
the wrong mixture, your engine could get too
hot but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.1. You can remove the coolant surge tank pressure
cap when the cooling system, including the coolant
surge tank pressure cap and upper radiator
hose, is no longer hot. Turn the pressure cap slowly
counterclockwise (left) about one-quarter of a
turn. If you hear a hiss, wait for that to stop.
This will allow any pressure still left to be vented
out the discharge hose.
2. Then keep turning the pressure cap slowly, and
remove it.
5-35
ProCarManuals.com

3. Fill the coolant surge tank with the proper
DEX-COOL®coolant mixture, to the cold ll line.4. With the coolant surge tank pressure cap off,
start the engine and let it run until you can feel
the upper radiator hose getting hot. Watch out for
the engine cooling fan.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
to the coolant surge tank until the level reaches the
cold ll line.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight.
Check the level in the surge tank when the cooling
system has cooled down. If the coolant isn’t at
the proper level, repeat Steps 1 through 3 and reinstall
the pressure cap. If the coolant isn’t at the proper
level when the system cools down again, see your
retailer.
5-36
ProCarManuals.com

Windshield Washer Fluid
What to Use
When you need windshield washer uid, be sure to read
the instructions before use. If you will be operating
your vehicle in an area where the temperature may fall
below freezing, use a uid that has sufficient protection
against freezing.
Adding Windshield Washer Fluid
Open the cap with this
symbol printed on it and
add washer uid until
the tank is full.Notice:
When using concentrated washer uid, follow
the manufacturer’s instructions for adding
water.
Do not mix water with ready-to-use washer uid.
Water can cause the solution to freeze and
damage your washer uid tank and other parts
of the washer system. Also, water does not
clean as well as washer uid.
Fill your washer uid tank only three-quarters
full when it is very cold. This allows for
expansion if freezing occurs, which could
damage the tank if it is completely full.
Do not use engine coolant (antifreeze) in your
windshield washer. It can damage your washer
system and paint.
5-37
ProCarManuals.com

Brakes
Brake Fluid
Your brake master cylinder reservoir is lled with DOT-3
brake uid. SeeEngine Compartment Overview on
page 5-12for the location of the reservoir.
There are only two reasons why the brake uid level
in the reservoir might go down. The rst is that the brake
uid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the uid
level goes back up. The other reason is that uid is
leaking out of the brake system or hydraulicclutch system if you have a manual transaxle. If it is,
you should have both systems checked and the
necessary repairs made, since a leak means that sooner
or later your brakes and/or clutch will not work well, or
will not work at all.
So, it isn noa good idea to “top off” your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add (or remove) brake uid, as necessary, only when
work is done on the brake and/or clutch hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake uid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-32.
5-38
ProCarManuals.com

Checking Brake Fluid
You can check the brake uid level without removing
the reservoir cap by just looking at the brake uid
reservoir. The uid level should be at or below the MAX
ll mark. After work has been done on the brake
hydraulic system, make sure the level does not exceed
the MAX ll mark on the reservoir.
What to Add
When you do need brake uid, use only DOT-3 brake
uid. Use new brake uid from a sealed container
only. SeeRecommended Fluids and Lubricants on
page 6-14. Be sure to clean the brake uid reservoir cap
and the area around the cap before removing it.
This will help keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake uid.
Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system parts so
badly that they will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged.
Be careful not to spill brake uid on your
vehicle. If you do, wash it off immediately.
SeeAppearance Care on page 5-87.
5-39
ProCarManuals.com

4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle.
You will not need to access your battery for jump
starting. Your vehicle has a remote positive (+) jump
starting terminal for that purpose. The terminal is
located on the engine compartment fuse block.
SeeEngine Compartment Overview on page 5-12
for more information on location.
{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 ACDelco
®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 do not, 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.
5-43
ProCarManuals.com

{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 don’t 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
basic things you should know. Positive (+) will go to
positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (−) will go to a heavy,
unpainted metal engine part or to a remote
negative (−) terminal if the vehicle has one.
Don’t connect positive (+) to negative (−) or you’ll
get a short that would damage the battery and
maybe other parts, too. And don’t connect
the negative (−) cable to the negative (−) terminal
on the dead battery because this can cause sparks.6. Remove the terminal cover and connect the red
positive (+) cable to the positive (+) terminal of
the dead battery. Use a remote positive (+) terminal
if the vehicle has one. The positive (+) terminal
on your vehicle is covered by a red protector cap
which must be removed before you connect
the positive (+) jumper cable to the positive (+)
terminal of the dead battery.
5-44
ProCarManuals.com

7. Don’t 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.
Don’t let the other end touch anything until the next
step. The other end of the negative (−) cable
doesn’tgo to the dead battery. It goes to a heavy,
unpainted metal part or to a remote negative (−)
terminal on the vehicle with 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. The electrical
connection is just as good there, and the chance
of sparks getting back to the battery is much less.
5-45
ProCarManuals.com