engine SATURN ION 2006 Workshop Manual

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.
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 5-29.
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.
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Service............................................................5-3
Accessories and Modications..........................5-3
California Proposition 65 Warning.....................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside
of Your Vehicle...........................................5-4
Fuel................................................................5-4
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-5
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-6
Filling the Tank..............................................5-7
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
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...........................................5-25
Engine Coolant.............................................5-25
Coolant Surge Tank Pressure Cap..................5-29
Engine Overheating.......................................5-29Cooling System............................................5-31
Windshield Washer Fluid................................5-38
Brakes........................................................5-39
Battery........................................................5-42
Jump Starting...............................................5-43
Headlamp Aiming...........................................5-48
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps (Coupe)......................................5-49
Headlamps (Sedan)......................................5-50
Front Turn Signal, Parking and Daytime
Running Lamps (DRL) (Coupe)...................5-52
Front Turn Signal, Parking and Daytime
Running Lamps (DRL) (Sedan)....................5-53
Center High-Mounted Stoplamp (CHMSL).........5-54
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-54
Replacement Bulbs.......................................5-55
Windshield Wiper Blade Replacement..............5-56
Tires..............................................................5-57
Tire Sidewall Labeling...................................5-59
Tire Terminology and Denitions.....................5-62
Ination - Tire Pressure.................................5-64
Tire Inspection and Rotation...........................5-66
When It Is Time for New Tires.......................5-68
Buying New Tires.........................................5-68
Section 5 Service and Appearance Care
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Different Size Tires and Wheels......................5-70
Uniform Tire Quality Grading..........................5-70
Wheel Alignment and Tire Balance..................5-72
Wheel Replacement......................................5-72
Tire Chains..................................................5-74
If a Tire Goes Flat........................................5-75
Changing a Flat Tire.....................................5-76
Removing the Spare Tire and Tools................5-77
Removing the Flat Tire and Installing
the Spare Tire..........................................5-82
Storing a Flat or Spare Tire and Tools............5-87
Compact Spare Tire......................................5-90
Appearance Care............................................5-90
Cleaning the Inside of Your Vehicle.................5-90
Fabric/Carpet...............................................5-92
Instrument Panel, Vinyl, and Other
Plastic Surfaces........................................5-93
Care of Safety Belts......................................5-93
Weatherstrips...............................................5-93
Washing Your Vehicle...................................5-94
Cleaning Exterior Lamps/Lenses.....................5-94Finish Care..................................................5-94
Windshield and Wiper Blades.........................5-95
Aluminum Wheels.........................................5-95
Tires...........................................................5-96
Sheet Metal Damage.....................................5-96
Finish Damage.............................................5-96
Underbody Maintenance................................5-97
Chemical Paint Spotting.................................5-97
Vehicle Care/Appearance Materials..................5-98
Vehicle Identication......................................5-99
Vehicle Identication Number (VIN).................5-99
Service Parts Identication Label.....................5-99
Electrical System............................................5-99
Add-On Electrical Equipment..........................5-99
Windshield Wiper Fuses...............................5-100
Power Windows and Other Power Options......5-100
Fuses and Circuit Breakers..........................5-100
Floor Console Fuse Block............................5-100
Engine Compartment Fuse Block...................5-102
Capacities and Specications........................5-109
Section 5 Service and Appearance Care
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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.
Accessories and Modications
When you add non-Saturn accessories to your vehicle
they can affect your vehicle’s performance and
safety, including such things as, airbags, braking,
stability, ride and handling, emissions systems,
aerodynamics, durability, and electronic systems like
anti-lock brakes, traction control, and stability control.
Some of these accessories may even cause malfunction
or damage not covered by warranty.
Saturn accessories are designed to complement and
function with other systems on your vehicle. Your Saturn
retailer can accessorize your vehicle using genuine
Saturn accessories. When you go to your Saturn retailer
and ask for Saturn accessories, you will know that
Saturn-trained and supported service technicians will
perform the work using genuine Saturn accessories.
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.
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Doing Your Own Service Work
{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.
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 7-12.Your vehicle has an airbag system. Before attempting
to do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-66.
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 6-16.
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
The 8th digit of your vehicle identication number (VIN)
shows the code letter or number that identies your
engine. You will nd the VIN at the top left of the
instrument panel. SeeVehicle Identication Number
(VIN) on page 5-99.
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Gasoline Octane
If your vehicle has the 2.2L L4 engine (VIN Code F),
use regular unleaded gasoline with a posted octane
rating of 87 or higher. If the octane rating is less than 87,
you may notice an audible knocking noise when you
drive, commonly referred to as spark knock. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking, your
engine needs service.
If your vehicle has the 2.4L L4 engine (VIN Code B) or
the 2.0L Supercharged engine (VIN Code P), use
premium unleaded gasoline with a posted octane rating
of 91 or higher. You may also use regular unleaded
gasoline rated at 87 octane or higher, but your vehicle’s
acceleration may be slightly reduced, and you may
notice a slight audible knocking noise, commonly
referred to as spark knock. If the octane is less than 87,
you may notice 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. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking,
your engine needs service.
Gasoline Specications
At a minimum, gasoline should meet ASTM
specication D 4814 in the United States or
CAN/CGSB-3.5 in Canada. Some gasolines may
contain an octane-enhancing additive called
methylcyclopentadienyl manganese tricarbonyl (MMT).
General Motors recommends against the use of
gasolines containing MMT. SeeAdditives on page 5-6
for additional information.
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 3-36. 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.
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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.
To help keep fuel injectors and intake valves clean,
or if your vehicle experiences problems due to
dirty injectors or valves, look for gasoline that is
advertised as TOP TIER Detergent 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. General Motors recommends that you use
these gasolines if they comply with the specications
described earlier. However, E85 (85% ethanol) and other
fuels containing more than 10% ethanol must not be used
in vehicles that were not designed for those fuels.
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
recommends against 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.
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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.
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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.
Hood Release
To open the hood, do the following:
1. Pull the interior hood
release handle with
this symbol on it. It is
located to the left
of the steering column
below the instrument
panel.
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Engine Compartment Overview
When you open the hood on the 2.2L L4 engine (2.4L L4 engine similar), here is what you will see:
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