cooling SATURN RELAY 2005 User Guide

{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol,
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
Occasionally check the coolant level in the radiator. For
information on how to add coolant to the radiator,
seeCooling System on page 5-28.
Radiator Pressure Cap
Notice:The radiator cap on your vehicle is a
pressure-type cap and must be tightly installed to
prevent coolant loss and possible engine damage
from overheating. Be sure the arrows on the cap
line up with the overow tube on the radiator
ller neck.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Engine Overheating
You will nd an engine coolant temperature gage on
your vehicle’s instrument panel. SeeEngine Coolant
Temperature Gage on page 3-37.
Your vehicle may also have an ENGINE COOLANT
HOT message displayed in the Driver Information
Center (DIC). SeeDIC Warnings and Messages on
page 3-49.
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Cooling System
When you decide it is safe to lift the hood, here is what
you will see:
A. Radiator Pressure Cap
B. Electric Engine Cooling Fans
C. Coolant Recovery Tank{CAUTION:
An electric engine cooling fan under the hood
can start up even when the engine is not
running and can injure you. Keep hands,
clothing and tools away from any underhood
electric fan.
If the coolant inside the coolant recovery tank is boiling,
do not do anything else until it cools down. The
vehicle should be parked on a level surface.
The coolant level should be at or above the full cold
mark. If it is not, you may have a leak at the pressure
cap or in the radiator hoses, heater hoses, radiator,
water pump or somewhere else in the cooling system.
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{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.
If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fans are running.
If the engine is overheating, both fans should be
running. If they are not, your vehicle needs service.Notice:Engine damage from running your engine
without coolant is not covered by your warranty. See
Overheated Engine Protection Operating Mode on
page 5-27for information on driving to a safe place
in an emergency.
Notice:Using coolant other than DEX-COOL®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
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How to Add Coolant to the Coolant
Recovery Tank
If you have not found a problem yet, but the coolant
level is not at or above the full cold mark, add a
50/50 mixture of clean, drinkable water and DEX-COOL
®
engine coolant at the coolant recovery tank. See
Engine Coolant on page 5-22for more information.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
When the coolant in the coolant recovery tank is at or
above the full cold mark, start your vehicle.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
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If the overheat warning continues, there is one more
thing you can try. You can add the proper coolant
mixture directly to the radiator, but be sure the cooling
system is cool before you do it.
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the radiator
pressure cap — even a little — they can come
out at high speed. Never turn the cap when the
cooling system, including the radiator pressure
cap, is hot. Wait for the cooling system and
radiator pressure cap to cool if you ever have
to turn the pressure cap.
How to Add Coolant to the Radiator
Notice:Your engine has a specic radiator
ll procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.1. You can remove the radiator pressure cap when
the cooling system, including the radiator pressure
cap and upper radiator hose, is no longer hot.
Turn the pressure cap slowly counterclockwise until
it rst stops. Do not press down while turning the
pressure cap.
If you hear a hiss, wait for that to stop. A hiss
means there is still some pressure left.
2. Then keep turning the pressure cap, but now push
down as you turn it. Remove the pressure cap.
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6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fans.
7. By this time, the coolant level inside the radiator
ller neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the ller neck until the level reaches
the base of the ller neck.
8. Then replace the pressure cap. At any time during
this procedure if coolant begins to ow out of the ller
neck, reinstall the pressure cap. Be sure the arrows
on the pressure cap line up with the vent tube.9. Then ll the coolant recovery tank to the full
cold mark.
10. Put the cap back on the coolant recovery tank.
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Wheel Replacement
Replace any wheel that is bent, cracked or badly rusted
or corroded. If wheel nuts keep coming loose, the
wheel, wheel bolts and wheel nuts should be replaced.
If the wheel leaks air, replace it (except some
aluminum wheels, which can sometimes be repaired).
See your retailer if any of these conditions exist.
Your retailer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.
If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new Saturn
original equipment parts. This way, you will be sure to
have the right wheel, wheel bolts and wheel nuts
for your vehicle.{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-69for more
information.
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Capacities and Specications
The following approximate capacities are given in English and metric measurements. SeeRecommended Fluids and
Lubricants on page 6-12for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant Systems
Front A/C 1.7 lbs 0.8 kg
Front and Rear A/C 2.2 lbs 1.0 kg
Automatic Transaxle — Pan Removal and Replacement 7.4 quarts 7.0 L
AWD Automatic Transaxle — Pan Removal and
Replacement8.7 quarts 8.3 L
Cooling System
Front A/C 11.3 quarts 10.7 L
Front and Rear A/C 12.8 quarts 12.2 L
Engine Oil with Filter 4.0 quarts 3.8 L
Fuel Capacity
Regular 20.0 gallons 75.7 L
Extended 25.1 gallons 95.0 L
Wheel Nut Torque 100 ft lb 140Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual. Recheck uid level after lling.
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-13. Reset oil life
system. SeeEngine Oil Life System on page 5-16.An Emission Control
Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (k).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-18.See footnote (g).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 5-59and “Tire Wear Inspection” inAt Least Once a Month on
page 6-9.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels and 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).•
Check transaxle uid level and add uid as needed.•
Inspect throttle system.See footnote (j).•
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Additional Required Services
The following services should be performed at the rst maintenance service (IorII) after the indicated miles
(kilometers) shown for each item.
Additional Required Services
Service and Miles (Kilometers)25,000
(41 500)50,000
(83 000)75,000
(125 000)100,000
(166 000)125,000
(207 500)150,000
(240 000)
Inspect fuel system for damage
or leaks.• •••••
Inspect exhaust system for loose or
damaged components.• •••••
Replace engine air cleaner lter. See
Engine Air Cleaner/Filter on page 5-18.•••
Change automatic transaxle uid and
lter (severe service).See footnote (h).•••
Change automatic transaxle uid and
lter (normal service).•
Replace spark plugs and inspect spark
plug wires.An Emission Control
Service.•
Engine cooling system service (or every
ve years, whichever occurs rst).
An Emission Control Service.
See footnote (i).•
Inspect engine accessory drive belt.
An Emission Control Service.
See footnote (m).•
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