brake SATURN OUTLOOK 2009 Service Manual

Filling a Portable Fuel
Container
{CAUTION
Never ll a portable fuel container
while it is in the vehicle. Static
electricity discharge from the
container can ignite the fuel vapor.
You can be badly burned and the
vehicle damaged if this occurs. To
help avoid injury to you and others:
Dispense fuel 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.
(Continued)
CAUTION (Continued)
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 fuel.
Do not use a cellular phone
while pumping fuel.
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.
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A. Radiator Pressure Cap. See
Cooling System on page 5-19.
B. Engine Coolant Recovery Cap.
SeeCooling System on
page 5-19.
C. Remote Negative (−) Terminal.
SeeJump Starting on page 5-30.
D.Underhood Fuse Block on
page 5-94.
E. Remote Positive (+) Terminal.
SeeJump Starting on page 5-30.
F.Power Steering Fluid on
page 5-25.
G. Engine Oil Fill Cap. See “When
to Add Engine Oil” underEngine
Oil on page 5-13.H. Engine Oil Dipstick. See
“Checking Engine Oil” under
Engine Oil on page 5-13.
I. Automatic Transmission Fluid
Dipstick. See “Checking the
Fluid Level” underAutomatic
Transmission Fluid on page 5-18.
J. Brake Master Cylinder Reservoir.
See “Brake Fluid” underBrakes
on page 5-27.
K.Engine Air Cleaner/Filter on
page 5-17.
L. Windshield Washer Fluid
Reservoir. See “Adding Washer
Fluid” underWindshield
Washer Fluid on page 5-26.Engine Oil
Checking Engine Oil
It is a good idea to check the engine
oil level at each fuel ll. 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. SeeEngine
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 this is not done,
the oil dipstick might not show the
actual level.
2. Pull out the dipstick and clean
it with a paper towel or cloth,
then push it back in all the way.
Remove it again, keeping the
tip down, and check the level.
Service and Appearance Care 5-13
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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 the washer uid tank only
three-quarters full when it is
very cold. This allows for uid
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 the
vehicle’s windshield washer
system and paint.
Brakes
Brake Fluid
The brake master cylinder 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 brake uid level goes down
because of normal brake lining
wear. When new linings are
installed, the uid level goes
back up.
A uid leak in the brake hydraulic
system can also cause a low uid
level. Have the brake hydraulic
system xed, since a leak means
that sooner or later the brakes will
not work well.Do not top off the brake uid. Adding
uid does not correct a leak. If uid
is added when the linings are worn,
there will be too much uid when new
brake linings are installed. Add or
remove brake uid, as necessary,
only when work is done on the brake
hydraulic system.
{CAUTION
If too much brake uid is added, it
can spill on the engine and burn, if
the engine is hot enough. You or
others could be burned, and the
vehicle could be damaged. Add
brake uid only when work is done
on the brake hydraulic system.
When the brake uid falls to a low
level, the brake warning light comes
on. SeeBrake System Warning
Light on page 3-36.
Service and Appearance Care 5-27
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What to Add
Use only new DOT 3 brake uid
from a sealed container. See
Recommended Fluids and
Lubricants on page 6-12.
Always clean the brake uid reservoir
cap and the area around the cap
before removing it. This helps keep
dirt from entering the reservoir.
{CAUTION
With the wrong kind of uid in the
brake hydraulic system, the
brakes might not work well. This
could cause a crash. Always use
the proper brake uid.Notice:
Using the wrong uid can badly
damage brake hydraulic system
parts. For example, just a few
drops of mineral-based oil,
such as engine oil, in the brake
hydraulic system can damage
brake hydraulic system parts so
badly that they will have to be
replaced. Do not let someone
put in the wrong kind of uid.
If brake uid is spilled on the
vehicle’s painted surfaces, the
paint nish can be damaged. Be
careful not to spill brake uid
on the vehicle. If you do, wash it
off immediately. SeeWashing
Your Vehicle on page 5-87.
Brake Wear
This vehicle has 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 can come and go or be
heard all the time the vehicle is
moving, except when applying the
brake pedal rmly.
{CAUTION
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
an accident. When the brake wear
warning sound is heard, have the
vehicle serviced.
Notice:Continuing to drive with
worn-out brake pads could
result in costly brake repair.
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Some driving conditions or climates
can cause a brake squeal when
the brakes are rst applied or lightly
applied. This does not mean
something is wrong with the 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 torque
specications inCapacities and
Specifications on page 5-98.
Brake linings should always be
replaced as complete axle sets.
Brake Pedal Travel
See your dealer/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 that brake service might
be required.
Brake Adjustment
Every time the brakes are applied,
with or without the vehicle moving,
the brakes adjust for wear.
Replacing Brake System Parts
The braking system on a vehicle
is complex. Its many parts have to
be of top quality and work well
together if the vehicle is to have
really good braking. The vehicle was
designed and tested with top-quality
brake parts. When parts of the
braking system are replaced — for
example, when the brake linings
wear down and new ones are
installed — be sure to get new
approved replacement parts. If this
is not done, the brakes might
not work properly. For example, if
someone puts in brake linings
that are wrong for the vehicle, the
balance between the front and
rear brakes can change — for the
worse. The braking performance
expected can change in many other
ways if the wrong replacement
brake parts are installed.
Battery
This vehicle has a maintenance free
battery. When it is time for a new
battery, see your dealer/retailer
for one that has the replacement
number shown on the original
battery’s label.
For battery replacement, see your
dealer/retailer or the service manual.
To purchase a service manual,
seeService Publications Ordering
Information on page 7-15.
Warning:Battery posts, terminals,
and related accessories contain
lead and lead compounds,
chemicals known to the State of
California to cause cancer and
reproductive harm. Wash hands
after handling.
Service and Appearance Care 5-29
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To avoid the possibility of the
vehicles rolling, set the parking
brake rmly on both vehicles
involved in the jump start
procedure. Put an automatic
transmission in P (Park) or
a manual transmission in
Neutral before setting the parking
brake. If one of the vehicles is a
four-wheel-drive vehicle, be sure
the transfer case is not in Neutral.
Notice:If you leave the radio or
other accessories on during
the jump starting procedure, they
could be damaged. The repairs
would not be covered by the
warranty. Always turn off
the radio and other accessories
when jump starting the vehicle.3. Turn off the ignition on both
vehicles. Unplug unnecessary
accessories plugged into the
cigarette lighter or the accessory
power outlets. Turn off the radio
and all lamps that are not needed.
This will avoid sparks and help
save both batteries. And it could
save the radio!
4. Open the hoods and locate the
positive (+) and negative (−)
terminal locations on the other
vehicle. Your vehicle has a
remote positive (+) and a remote
negative (−) jump starting
terminal. SeeEngine
Compartment Overview on
page 5-12for more information
on the terminal locations.{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 batteries have enough
water. You do not need to add
water to the ACDelco
®battery
(or batteries) 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.
Service and Appearance Care 5-31
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Tire Size
The following illustration shows
an example of a typical
passenger vehicle tire size.
(A) Passenger (P-Metric) Tire
:The United States version of a
metric tire sizing system. The
letter P as the rst character in
the tire size means a passenger
vehicle tire engineered to
standards set by the U.S. Tire
and Rim Association.
(B) Tire Width
:The three-digit
number indicates the tire section
width in millimeters from sidewall
to sidewall.(C) Aspect Ratio
:A two-digit
number that indicates the tire
height-to-width measurements.
For example, if the tire size
aspect ratio is 60, as shown in
item C of the illustration, it would
mean that the tire’s sidewall is
60 percent as high as it is wide.
(D) Construction Code
:A letter
code is used to indicate the type
of ply construction in the tire.
The letter R means radial ply
construction; the letter D means
diagonal or bias ply construction;
and the letter B means
belted-bias ply construction.
(E) Rim Diameter
:Diameter of
the wheel in inches.
(F) Service Description
:These
characters represent the load
index and speed rating of the tire.
The load index represents the
load carry capacity a tire is
certied to carry. The speed
rating is the maximum speed a
tire is certied to carry a load.
Tire Terminology and
Denitions
Air Pressure:The amount of
air inside the tire pressing
outward on each square inch
of the tire. Air pressure is
expressed in pounds per square
inch (psi) or kilopascal (kPa).
Accessory Weight
:This means
the combined weight of optional
accessories. Some examples
of optional accessories are,
automatic transmission, power
steering, power brakes, power
windows, power seats, and air
conditioning.
Aspect Ratio
:The relationship
of a tire’s height to its width.
Belt
:A rubber coated layer of
cords that is located between the
plies and the tread. Cords may
be made from steel or other
reinforcing materials.
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TPMS Sensor Matching
Process
Each TPMS sensor has a unique
identication code. Any time you
rotate your vehicle’s tires or replace
one or more of the TPMS sensors,
the identication codes will need to
be matched to the new tire/wheel
position. The sensors are matched
to the tire/wheel positions in the
following order: driver side front tire,
passenger side front tire, passenger
side rear tire, and driver side rear
tire using a TPMS diagnostic tool.
See your dealer/retailer for service.
The TPMS sensors can also be
matched to each tire/wheel position
by increasing or decreasing the
tire’s air pressure. If increasing the
tire’s air pressure, do not exceed
the maximum ination pressure
indicated on the tire’s sidewall.
To decrease air-pressure out of
a tire you can use the pointed end
of the valve cap, a pencil-style
air pressure gage, or a key.You have two minutes to match
the rst tire/wheel position, and
ve minutes overall to match all
four tire/wheel positions. If it takes
longer than two minutes, to match
the rst tire and wheel, or more than
ve minutes to match all four tire
and wheel positions the matching
process stops and you need to
start over.
The TPMS sensor matching process
is outlined below:
1. Set the parking brake.
2. Turn the ignition switch to
ON/RUN with the engine off.
3. Press the Remote Keyless
Entry (RKE) transmitter’s LOCK
and UNLOCK buttons at the
same time for approximately
ve seconds. The horn sounds
twice to signal the receiver
is in relearn mode and TIRE
LEARNING ACTIVE message
displays on the DIC screen.4. Start with the driver side front tire.
5. Remove the valve cap from
the valve cap stem. Activate the
TPMS sensor by increasing or
decreasing the tire’s air pressure
for ve seconds, or until a horn
chirp sounds. The horn chirp,
which may take up to 30 seconds
to sound, conrms that the sensor
identication code has been
matched to this tire and wheel
position.
6. Proceed to the passenger
side front tire, and repeat
the procedure in Step 5.
7. Proceed to the passenger
side rear tire, and repeat
the procedure in Step 5.
Service and Appearance Care 5-51
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GM’s exclusive TPC Spec
system considers over a dozen
critical specications that
impact the overall performance
of your vehicle, including
brake system performance, ride
and handling, traction control,
and tire pressure monitoring
performance. GM’s TPC Spec
number is molded onto the
tire’s sidewall near the tire size.
If the tires have an all-season
tread design, the TPC Spec
number will be followed by an
MS for mud and snow. SeeTire
Sidewall Labeling on page 5-40
for additional information.
GM recommends replacing tires
in sets of four. This is because
uniform tread depth on all tires
will help keep your vehicle
performing most like it did when
the tires were new. Replacing
less than a full set of tires can
affect the braking and handling
performance of your vehicle.SeeTire Inspection and Rotation
on page 5-52for information on
proper tire rotation.
{CAUTION
Mixing tires could cause you
to lose control while driving.
If you mix tires of different
sizes, brands, or types (radial
and bias-belted tires), the
vehicle may not handle
properly, and you could have a
crash. Using tires of different
sizes, brands, or types may
also cause damage to your
vehicle. Be sure to use the
correct size, brand, and type of
tires on all wheels. It is all right
to drive with your compact
spare temporarily, as it was
developed for use on your
vehicle. SeeCompact Spare
Tire on page 5-83.
{CAUTION
If you use bias-ply tires on the
vehicle, the wheel rim anges
could develop cracks after
many miles of driving. A tire
and/or wheel could fail
suddenly, causing a crash.
Use only radial-ply tires with
the wheels on the vehicle.
If you must replace your vehicle’s
tires with those that do not have
a TPC Spec number, make sure
they are the same size, load
range, speed rating, and
construction type (radial and
bias-belted tires) as your
vehicle’s original tires.
Vehicles that have a tire pressure
monitoring system could give an
inaccurate low-pressure warning
if non-TPC Spec rated tires are
installed on your vehicle.
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Non-TPC Spec rated tires may
give a low-pressure warning that
is higher or lower than the proper
warning level you would get with
TPC Spec rated tires. SeeTire
Pressure Monitor System on
page 5-46.
Your vehicle’s original equipment
tires are listed on the Tire and
Loading Information Label.
SeeLoading the Vehicle on
page 4-18, for more information
about the Tire and Loading
Information Label and its location
on your vehicle.Different Size Tires and
Wheels
If you add wheels or tires that
are a different size than your original
equipment wheels and tires, this may
affect the way your vehicle performs,
including its braking, ride and
handling characteristics, stability,
and resistance to rollover.
Additionally, if your vehicle has
electronic systems such as, anti-lock
brakes, rollover airbags, traction
control, and stability control, the
performance of these systems can
be affected.
{CAUTION
If you add different sized
wheels, your vehicle may not
provide an acceptable level of
performance and safety if tires not
recommended for those wheels
are selected. You may increase
the chance that you will crash and
suffer serious injury. Only use
Saturn specic wheel and tire
systems developed for your
vehicle, and have them properly
installed by a Saturn certied
technician.
SeeBuying New Tires on page 5-54
andAccessories and Modifications
on page 5-3for additional
information.
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