SATURN ION 2005 Owners Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling the Tank..............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-15
Engine Oil Life System..................................5-20
Engine Air Cleaner/Filter................................5-22
Automatic Transaxle Fluid..............................5-24
Manual Transaxle Fluid..................................5-24
Hydraulic Clutch...........................................5-24
Engine Coolant.............................................5-24
Coolant Surge Tank Pressure Cap..................5-27
Engine Overheating.......................................5-28
Cooling System............................................5-30Windshield Washer Fluid................................5-37
Brakes........................................................5-38
Battery........................................................5-41
Jump Starting...............................................5-42
Headlamp Aiming...........................................5-46
Bulb Replacement..........................................5-47
Halogen Bulbs..............................................5-47
Headlamps (Coupe)......................................5-47
Headlamps (Sedan)......................................5-48
Front Turn Signal Lamps (Sedan)...................5-50
Front Turn Signal and Parking
Lamps (Coupe).........................................5-51
Fog Lamps..................................................5-52
Sidemarker Lamps (Coupe)............................5-52
Center High-Mounted Stoplamp (CHMSL).........5-53
Taillamps, Stoplamps and Back-up Lamps........5-54
Replacement Bulbs.......................................5-55
Windshield Wiper Blade Replacement..............5-55
Tires..............................................................5-56
Tire Sidewall Labelling...................................5-58
Tire Terminology and Denitions.....................5-60
Ination - Tire Pressure.................................5-63
Tire Inspection and Rotation...........................5-65
When It Is Time for New Tires.......................5-66
Section 5 Service and Appearance Care
5-1
ProCarManuals.com

Buying New Tires.........................................5-67
Uniform Tire Quality Grading..........................5-68
Wheel Alignment and Tire Balance..................5-69
Wheel Replacement......................................5-69
Tire Chains..................................................5-71
If a Tire Goes Flat........................................5-72
Changing a Flat Tire.....................................5-73
Removing the Spare Tire and Tools................5-74
Removing the Flat Tire and Installing the
Spare Tire................................................5-77
Storing a Flat or Spare Tire and Tools............5-81
Compact Spare Tire......................................5-83
Appearance Care............................................5-83
Cleaning the Inside of Your Vehicle.................5-84
Fabric/Carpet...............................................5-85
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-86
Care of Safety Belts......................................5-86
Weatherstrips...............................................5-86
Washing Your Vehicle...................................5-87
Cleaning Exterior Lamps/Lenses.....................5-87Finish Care..................................................5-87
Windshield and Wiper Blades.........................5-88
Aluminum Wheels.........................................5-88
Tires...........................................................5-89
Sheet Metal Damage.....................................5-89
Finish Damage.............................................5-89
Underbody Maintenance................................5-90
Chemical Paint Spotting.................................5-90
Vehicle Care/Appearance Materials..................5-91
Vehicle Identication......................................5-92
Vehicle Identication Number (VIN).................5-92
Service Parts Identication Label.....................5-92
Electrical System............................................5-93
Add-On Electrical Equipment..........................5-93
Windshield Wiper Fuses................................5-93
Power Windows and Other Power Options.......5-93
Fuses and Circuit Breakers............................5-93
Instrument Panel Fuse Block..........................5-94
Engine Compartment Fuse Block....................5-96
Capacities and Specications........................5-100
Section 5 Service and Appearance Care
5-2
ProCarManuals.com

Service
Your Saturn retailer knows your vehicle best and wants
you to be happy with it. We hope you will go to your
retailer for all your service needs. You will get genuine
Saturn parts and Saturn-trained and supported
service people.
We hope you will want to keep your Saturn vehicle all
Saturn.
Genuine Saturn parts have one of these marks.
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3
ProCarManuals.com

Doing Your Own Service Work
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-9.
Your vehicle has an airbag system. Before attempting to
do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-58.
You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeeMaintenance Record on page 6-17.{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts,
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts, and
other fasteners. English and metric
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
5-4
ProCarManuals.com

Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle
can affect the airow around it. This may cause
wind noise and affect windshield washer performance.
Check with your retailer before adding equipment to
the outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
If your vehicle has the 2.2L L4 engine, use regular
unleaded gasoline with a posted octane of 87 or higher.
If the octane is less than 87, you may get a heavy
knocking noise when you drive. If this occurs, use a
gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine. A
little pinging noise when you accelerate or drive
uphill is considered normal. This does not indicate a
problem exists or that a higher-octane fuel is necessary.
If you are using 87 octane or higher-octane fuel and
hear heavy knocking, your engine needs service.
If your vehicle has the 2.0L Supercharged engine, use
premium unleaded gasoline with a posted octane of
91 or higher for best performance. You may also
use middle grade or regular unleaded gasoline rated at
87 octane or higher, but your vehicle’s acceleration
may be slightly reduced. If the octane is less than 87,
you may get a heavy knocking noise when you drive. If
this occurs, use a gasoline rated at 87 octane or
higher as soon as possible. Otherwise, you might
damage your engine.
5-5
ProCarManuals.com

Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide Fuel
Charter which is available from the Alliance of Automobile
Manufacturers at www.autoalliance.org/fuel_charter.htm.
Gasoline meeting these specications could provide
improved driveability and emission control system
performance compared to other gasoline.
California Fuel
If your vehicle is certied to meet California Emissions
Standards, it is designed to operate on fuels that
meet California specications. See the underhood
emission control label. If this fuel is not available
in states adopting California emissions standards, your
vehicle will operate satisfactorily on fuels meeting
federal specications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on and your vehicle may fail a
smog-check test. SeeMalfunction Indicator Lamp on
page 3-33. If this occurs, return to your authorized
Saturn retailer for diagnosis. If it is determined that the
condition is caused by the type of fuel used, repairs
may not be covered by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. In most cases, you should not have to add
anything to your fuel. However, some gasolines contain
only the minimum amount of additive required to
meet U.S. Environmental Protection Agency regulations.
General Motors recommends that you buy gasolines
that are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems
due to dirty injectors or valves, try a different brand of
gasoline. Also, your retailer has additives that will
help correct and prevent most deposit-related problems.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specications described earlier.
5-6
ProCarManuals.com

Notice:Your vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in your fuel
system and also damage the plastic and rubber
parts. That damage would not be covered under
your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask the attendant where you buy
gasoline whether the fuel contains MMT. General Motors
does not recommend the use of such gasolines.
Fuels containing MMT can reduce the life of spark plugs
and the performance of the emission control system
may be affected. The malfunction indicator lamp
may turn on. If this occurs, return to your authorized
Saturn retailer for service.Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
5-7
ProCarManuals.com

Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames, and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.The tethered fuel cap is located behind a hinged fuel
door on the passenger’s side of the vehicle.
To remove the fuel cap, turn it slowly counterclockwise.
The fuel cap has a spring in it; if the cap is released
too soon, it will spring back to the right.
While refueling, let the fuel cap hang by the tether
below the fuel ll opening.
5-8
ProCarManuals.com

{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly.
This spray can happen if your tank is nearly
full, and is more likely in hot weather. Open
the fuel cap slowly and wait for any hiss noise
to stop. Then unscrew the cap all the way.
Be careful not to spill fuel. Do not top off or overll the
tank and wait a few seconds after you have nished
pumping before removing the nozzle. Clean fuel
from painted surfaces as soon as possible. See
Washing Your Vehicle on page 5-87.
When replacing the fuel cap, turn it clockwise until it
clicks. Make sure the cap is fully installed. The
diagnostic system can determine if the fuel cap has
been left off or improperly installed. This would allow fuel
to evaporate into the atmosphere. SeeMalfunction
Indicator Lamp on page 3-33.In addition, the CHECK GAS CAP message will be
displayed in the Message Center if the fuel cap is not
properly reinstalled. SeeCheck Gas Cap Message
on page 3-43for more information.
{CAUTION:
If a re starts while you are refueling, do not
remove the nozzle. Shut off the ow of fuel by
shutting off the pump or by notifying the
station attendant. Leave the area immediately.
Notice:If you need a new fuel cap, be sure to get
the right type. Your dealer can get one for you.
If you get the wrong type, it may not t properly.
This may cause your malfunction indicator lamp to
light and may damage your fuel tank and emissions
system. SeeMalfunction Indicator Lamp on
page 3-33.
5-9
ProCarManuals.com

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed, or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
5-10
ProCarManuals.com