brakes SATURN ION 2005 Owner's Manual

Turn Signals When Towing a Trailer
When you tow a trailer, your vehicle may need a
different turn signal asher and/or extra wiring. See your
retailer if you need information. The arrows on your
instrument panel will ash whenever you signal a turn or
lane change. Properly hooked up, the trailer lamps
will also ash, telling other drivers you’re about to turn,
change lanes or stop.
When towing a trailer, the arrows on your instrument
panel will ash for turns even if the bulbs on the trailer
are burned out. Thus, you may think drivers behind
you are seeing your signal when they are not. It’s
important to check occasionally to be sure the trailer
bulbs are still working.
Driving on Grades
Notice:Do not tow on steep continuous grades
exceeding 6 miles (9.6 km). Extended, higher
than normal engine and transaxle temperatures may
result and damage your vehicle. Frequent stops
are very important to allow the engine and transaxle
to cool.
Reduce speed and shift to a lower gear before you start
down a long or steep downgrade. If you don’t shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
On a long uphill grade, shift down and reduce your
speed to around 45 mph (70 km/h) to reduce the
possibility of the engine and the transmission
overheating. If your engine does overheat, seeEngine
Overheating on page 5-28.
4-42
ProCarManuals.com

Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) for an automatic transaxle, or into gear for
a manual transaxle.
When parking uphill, turn your wheels away from
the curb. When parking downhill, turn your wheels
into the curb.
2. Have someone place chocks behind the trailer
wheels.
3. When the chocks are in place, release the regular
brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake and shift into PARK (P) for an
automatic transaxle or REVERSE (R) for a manual
transaxle.
5. Release the regular brakes.
4-43
ProCarManuals.com

When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. SeeScheduled Maintenance on
page 6-4for more information. Things that are especially
important in trailer operation are automatic transaxle
uid (don’t overll), engine oil, axle lubricant, drive belt,
cooling system and brake system. Each of these is
covered in this manual, and the Index will help you nd
them quickly. If you’re trailering, it’s a good idea to
review this information before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Engine Cooling When Trailer Towing
Your cooling system may temporarily overheat during
severe operating conditions. SeeEngine Overheating on
page 5-28.
Changing a Tire When Trailer Towing
If you get a at tire while towing a trailer, be sure
to secure the trailer and disconnect it from the vehicle
before changing the tire.
4-44
ProCarManuals.com

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

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
B. Engine Oil Dipstick (Out of View). See “Checking
Engine Oil” underEngine Oil on page 5-15.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
D. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-38andHydraulic Clutch
on page 5-24.E. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-96.
F. Remote Positive (+) Terminal. SeeJump Starting on
page 5-42.
G. Engine Coolant Surge Tank. SeeEngine Coolant on
page 5-24.
H. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-37.
5-13
ProCarManuals.com

A. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-15.
B. Electric Engine Cooling Fan. SeeCooling System on
page 5-30.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
D. Intercooler System Pressure Cap. SeeEngine
Coolant on page 5-24.
E. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-38andHydraulic Clutch
on page 5-24.
F. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
G. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-96.
H. Remote Positive (+) Terminal. SeeJump Starting on
page 5-42.
I. Engine Coolant Surge Tank. SeeCoolant Surge
Tank Pressure Cap on page 5-27.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-37.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull out the dipstick, clean it with a paper towel or
cloth and then push it back in all the way.
3. Pull out the dipstick again, keeping the tip down,
and check the level.
5-15
ProCarManuals.com

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 your retailer’s service
department and have it repaired as soon as possible.
Change the uid and lter at the intervals listed in
Additional Required Services on page 6-6, and be sure
to use the transaxle uid listed inRecommended
Fluids and Lubricants on page 6-14.
Notice:Use of the incorrect automatic transaxle
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transaxle uid listed in
Recommended Fluids and Lubricants on page 6-14.
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.
SeeRecommended Fluids and Lubricants on page 6-14
for 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.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for ve years or 150,000 miles
(240 000 km), whichever occurs rst, if you add only
DEX-COOL
®extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating on
page 5-28.
5-24
ProCarManuals.com

Brakes
Brake Fluid
The hydraulic clutch and
brake master cylinder use
the same reservoir.
The reservoir is lled with
DOT-3 brake uid. See
Engine 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 hydraulic
clutch 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 is not a 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
and/or clutch hydraulic system.
When your brake uid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-30.
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.
Always 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 5-83.
5-39
ProCarManuals.com

Brake Wear
Your vehicle has front disc brakes and may have rear
drum brakes or rear disc 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.
5-40
ProCarManuals.com