brake SATURN ION 2006 Repair Manual

Fuses Usage
7 Not Used
8Anti-lock Brake System, Traction
Control Module
9 Engine Control Module
10Canister Purge Solenoid, Canister
Vent Solenoid, Low Coolant Switch,
Oxygen Sensors
11Electric Ignition Control Module,
Charging System, Neutral Stop
Back-Up Switch
12 Not Used
13 Transaxle
14Transaxle Control Module, Neutral
Stop Back-Up
15 PRNDL, Back-up Switch
16 Fuel Injectors (Cylinder 1, 2, 3, 4)
17 Fog Lamps
18 Driver’s Side Headlamp
19 Windshield WiperFuses Usage
20 Horn
21Entertainment, Premium Radio
Amplier
22Anti-lock Brake System, Traction
Control Module
23 Rear Defogger
38 Starter/Ignition
39 Body Control Module 1
40Anti-lock Brake System, Traction
Control Module
41 Body Control Module 2
42 Not Used
43 Electric Power Steering
44 Air Pump Relay Fuse
45 Cooling Fan
46 Crank
47 Body Control Module 1A
48 Body Control Module (IGN 3)
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Fuses Usage
8 Anti-lock Brake System
9 Engine Control Module
10Canister Purge Solenoid, Canister
Vent Solenoid, Low Coolant Switch,
Oxygen Sensors
11Electric Ignition Control Module,
Charging System, Neutral Safety
Stop Back-Up Switch
12 Not Used
13 Engine Control Module
14 Boost
15 Back-up Switch
16 Fuel Injectors
17 Fog Lamps
18 Driver’s Side Headlamp
19 Windshield Wiper
20 HornFuses Usage
21Entertainment, Premium Radio
Amplier
22 Anti-lock Brake System
23 Rear Defogger
38 Starter/Ignition
39 Body Control Module 1
40 Anti-lock Brake System
41 Body Control Module 2
42 Not Used
43 Electric Power Steering
44 Cooling Fan 2
45 Cooling Fan 1
46 Crank
47 Body Control Module 1A
48 Body Control Module (IGN 3)
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Relays Usage
24 Air Conditioning Clutch
25 Horn
26 Fog Lamps
27 After Cooler Pump
28 Starter/Crank
29 Powertrain
30 Engine Cooling Fan 1
31 Engine Control Module
32 Wiper System 1
33 Wiper System 2
34 Rear Window Defogger
Diodes Usage
35
§Air Conditioning Diode
36
§Not Used
37
§Wiper Diode
Miscellaneous Usage
49 Fuse Puller
2.4L LE5 Engine
Fuses Usage
1Engine Control Module, Transaxle
Control Module
2 Not Used
3 Not Used
4 Passenger’s Side Headlamp
5 Air Conditioning
6 Not Used
7 Not Used
8Anti-lock Brake System, Traction
Control Module
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Fuses Usage
9Engine Control Module, Electronic
Throttle Control
10Canister Purge Solenoid, Canister
Vent Solenoid, Low Coolant Switch,
Oxygen Sensors
11Electric Ignition Control Module,
Charging System, Neutral Stop
Back-Up Switch
12 Not Used
13 Transaxle 2
14Transaxle Control Module, Neutral
Stop Back-Up
15 PRNDL, Back-up Switch
16 Fuel Injectors (Cylinder 1, 2, 3, 4)
17 Fog Lamps
18 Driver’s Side Headlamp
19 Windshield Wiper
20 HornFuses Usage
21Entertainment, Premium Radio
Amplier
22Anti-lock Brake System, Traction
Control Module
23 Rear Defogger
38 Starter/Ignition
39 Body Control Module 1
40Anti-lock Brake System, Traction
Control Module
41 Body Control Module 2
42 Not Used
43 Electric Power Steering
44 Cooling Fan 2
45 Cooling Fan
46 Crank
47 Body Control Module 1A
48 Body Control Module (IGN 3)
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-15. Reset oil life system.
SeeEngine Oil Life System on page 5-20.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.See footnote (l).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 5-66and “Tire Wear Inspection” inAt Least Once a Month
on page 6-10.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels. If you have the
2.0L L4 supercharged engine, check intercooler uid level. 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/shoes 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 wiper blades 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 airbag
coverings, and have them repaired or replaced.
The airbag 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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Engine Coolant Level Check
Check the engine coolant level and add DEX-COOL®
coolant mixture if necessary. SeeEngine Coolant
on page 5-25for further details.
Intercooler Coolant Level Check
(2.0L Supercharged Engine)
Check the coolant level and add DEX-COOL®coolant
mixture if necessary. SeeEngine Coolant on page 5-25
for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer uid reservoir and add the proper uid if
necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your vehicle’s tires and make sure they
are inated to the correct pressures. Do not forget to
check the spare tire. SeeTires on page 5-57for further
details. Check to make sure the spare tire is stored
securely. SeeChanging a Flat Tire on page 5-76.
Tire Wear Inspection
Tire rotation may be required for high mileage highway
drivers prior to the Engine Oil Life System service
notication. Check the tires for wear and, if necessary,
rotate the tires. SeeTire Inspection and Rotation on
page 5-66.
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 2-27.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
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3. On automatic transaxle vehicles, try to start the
engine in each gear. The vehicle should start
only in PARK (P) or NEUTRAL (N). If the vehicle
starts in any other position, contact your Saturn
retailer for service.
On manual transaxle vehicles, put the shift lever in
NEUTRAL, push the clutch pedal down halfway, and
try to start the engine. The vehicle should start only
when the clutch pedal is pushed down all the way to
the oor. If the vehicle starts when the clutch is not
pushed all the way down, contact your Saturn retailer
for service.
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 2-27.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the ignition to RUN, 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 to LOCK in each shift lever position.
With an automatic transaxle, the ignition should turn
to LOCK only when the shift lever is in PARK (P).
The key should come out only in LOCK.
With a manual transaxle, the key should come out
only in LOCK.
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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Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Windshield
WasherOptikleen
®Washer Solvent.
Parking Brake
Cable GuidesChassis Lubricant
(GM Part No. 12377985,
in Canada 88901242) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Hydraulic Clutch
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Manual
Transaxle
(2.2L and 2.4L
L4 engines)DEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specication”
on the label.
Manual
Transaxle
(2.0L L4
Supercharged
engine)Manual Transmission Fluid
(Part No. 21018899).
Automatic
TransaxleDEXRON
®-VI Automatic
Transmission Fluid.
Usage Fluid/Lubricant
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
Hood Latch
Assembly,
Secondary
Latch,
Pivots, Spring
Anchor, and
Release PawlLubriplate Lubricant Aerosol
(Saturn Part No. 21038869 or
GM Part No. U.S. 12346293,
in Canada 992723) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Hood, Trunk,
and Door
HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
Sunroof TrackLubriplate Lubricant Aerosol
(Saturn Part No. 21038869 or
GM Part No. U.S. 12346293,
in Canada 992723) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
Weatherstrip
ConditioningDielectric Silicone Grease
(GM Part No. U.S. 12345579,
in Canada 992887).
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