fuel SATURN RELAY 2005 Owner's Guide

Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline 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.
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 gasoline.
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.
5-10
ProCarManuals.com

A. Underhood Fuse Block. SeeUnderhood Fuse Block
on page 5-100.
B. Remote Positive (+) Terminal. SeeJump Starting on
page 5-40.
C. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-35.
D. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-25.
E. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-34.
F. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-13.
G. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-13.
H. Automatic Transaxle Fluid Dipstick. See “Checking
the Fluid Level” underAutomatic Transaxle Fluid
on page 5-19.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-36.
J. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-18.
K. Engine Coolant Recovery Tank. SeeCooling System
on page 5-28.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 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.
5-13
ProCarManuals.com

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.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure in
a tire, measured in pounds per square inch (psi) or
kilopascals (kPa) before a tire has built up heat
from driving. SeeInation - Tire Pressure on page 5-58.
Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation (DOT) motor vehicle
safety standards. The DOT code includes the Tire
Identication Number (TIN), an alphanumeric designator
which can also identify the tire manufacturer, production
plant, brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-31.GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-31.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-31.
Intended Outboard Sidewall:The side of an
asymmetrical tire, that must always face outward when
mounted on a vehicle.
Kilopascal (kPa):The metric unit for air pressure.
Light Truck (LT-Metric) Tire:A tire used on light duty
trucks and some multipurpose passenger vehicles.
Load Index:An assigned number ranging from 1 to 279
that corresponds to the load carrying capacity of a tire.
Maximum Ination Pressure:The maximum air
pressure to which a cold tire may be inated. The
maximum air pressure is molded onto the sidewall.
Maximum Load Rating:The load rating for a tire at the
maximum permissible ination pressure for that tire.
Maximum Loaded Vehicle Weight:The sum of curb
weight; accessory weight; vehicle capacity weight;
and production options weight.
Normal Occupant Weight:The number of occupants a
vehicle is designed to seat multiplied by 150 lbs (68 kg).
SeeLoading Your Vehicle on page 4-31.
5-56
ProCarManuals.com

Ination - Tire Pressure
Tires need the correct amount of air pressure to operate
effectively.
Notice:Do not let anyone tell you that
under-ination or over-ination is all right. It is not.
If your tires do not have enough air (under-ination),
you can get the following:
Too much exing
Too much heat
Tire overloading
Premature or irregular wear
Poor handling
Reduced fuel economy
If your tires have too much air (over-ination), you
can get the following:
Unusual wear
Poor handling
Rough ride
Needless damage from road hazardsA Tire and Loading Information label is attached to the
vehicle’s center pillar (B-pillar), below the driver’s
door latch. This label shows your vehicle’s original
equipment tires and the correct ination pressures for
your tires when they are cold. The recommended
cold tire ination pressure, shown on the label, is the
minimum amount of air pressure needed to support your
vehicle’s maximum load carrying capacity.
For additional information regarding how much weight
your vehicle can carry, and an example of the tire
and loading information label, seeLoading Your Vehicle
on page 4-31. How you load your vehicle affects
vehicle handling and ride comfort, never load your
vehicle with more weight than it was designed to carry.
When to Check
Check your tires once a month or more. Do not forget to
check the compact spare tire, it should be at 60 psi
(420 kPa). For additional information regarding
the compact spare tire, seeCompact Spare Tire on
page 5-87.
5-58
ProCarManuals.com

Sheet Metal Damage
If the vehicle is damaged and requires sheet metal
repair or replacement, make sure the body repair shop
applies anti-corrosion material to parts repaired or
replaced to restore corrosion protection.
Original manufacturer replacement parts will provide the
corrosion protection while maintaining the warranty.
Finish Damage
Any stone chips, fractures or deep scratches in the
nish should be repaired right away. Bare metal
will corrode quickly and may develop into major repair
expense.
Minor chips and scratches can be repaired with touch-up
materials available from your Saturn retailer. Larger
areas of nish damage can be corrected in your Saturn
retailer’s body and paint shop.
Underbody Maintenance
Chemicals used for ice and snow removal and dust
control can collect on the underbody. If these are not
removed, corrosion and rust can develop on the
underbody parts such as fuel lines, frame, oor pan and
exhaust system even though they have corrosion
protection.
At least every spring, ush these materials from the
underbody with plain water. Clean any areas where mud
and debris can collect. Dirt packed in close areas of
the frame should be loosened before being ushed.
Your Saturn retailer or an underbody car washing
system can do this for you.
Chemical Paint Spotting
Some weather and atmospheric conditions can create a
chemical fallout. Airborne pollutants can fall upon and
attack painted surfaces on your vehicle. This damage
can take two forms: blotchy, ring-shaped discolorations,
and small, irregular dark spots etched into the paint
surface.
Although no defect in the paint job causes this, Saturn
will repair, at no charge to the owner, the surfaces
of new vehicles damaged by this fallout condition within
12 months or 12,000 miles (20 000 km) of purchase,
whichever occurs rst.
5-94
ProCarManuals.com

Fuses Usage
1 Right High Beam
2 Fuel Pump
3 Diode
SPARE Spare
SPARE Spare
4 Left High Beam
SPARE Spare
SPARE Spare
SPARE Spare
5 Not Used
6 Air Conditioning Clutch
7 Horn
8 Left Low Beam
9Powertrain Control Module,
Electronic Throttle Control
10 Not Used
11 Transmission Solenoid
12 Right Low BeamFuses Usage
13 Anti-lock Brake System
14 Powertrain Control Module Ignition
15 Electronic Ignition
16 Fuel Injector
17Climate Control, RPA, Cruise
Control
18 Electronic Throttle Control
19 Engine Sensor, Evaporator
20 Airbag
21 Not Used
22 Emission, All-Wheel Drive
23 Auxiliary Power
24 Front Windshield Washer
25 AC/DC Inverter
26 Rear Blower
27 Front Blower
28 Front Windshield Wiper
5-101
ProCarManuals.com

J-Case Fuses Usage
PLR Fuse Puller
29 Fan 1
30 Starter Solenoid
31 Anti-lock Brake System Motor
32 Blank
33 Fan 2
34 Front Blower High
35 Battery Main 3
36 Rear Defogger
37 Battery Main 2
38 Battery Main 1Relays Usage
RUN RLY Starter
LO BEAM Low Beam
FUEL PUMP Fuel Pump
HORN Horn
AC/CLTCH Air Conditioning Clutch
HI BEAM High Beam
PWR/TRN Powertrain
WPR2 Wiper 2
WPR1 Wiper 1
FAN 1 Fan 1
CRNK Crank
IGN MAIN Ignition Main
FAN2 Fan 2
FAN3 Fan 3
BLANK Not Used
5-102
ProCarManuals.com

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.
5-103
ProCarManuals.com

Maintenance Schedule......................................6-2
Introduction...................................................6-2
Maintenance Requirements..............................6-2
Your Vehicle and the Environment....................6-2
Using the Maintenance Schedule......................6-2
Scheduled Maintenance...................................6-4
Additional Required Services............................6-6
Maintenance Footnotes...................................6-7Owner Checks and Services............................6-8
At Each Fuel Fill............................................6-8
At Least Once a Month...................................6-9
At Least Once a Year.....................................6-9
Recommended Fluids and Lubricants...............6-12
Normal Maintenance Replacement Parts..........6-14
Maintenance Record.....................................6-15
Section 6 Maintenance Schedule
6-1
ProCarManuals.com

Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Maintenance Requirements
Notice:Maintenance intervals, checks, inspections,
replacement parts, and recommended uids and
lubricants as prescribed in this manual are
necessary to keep your vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance may not be covered by
warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance is
important. Improper vehicle maintenance can even
affect the quality of the air we breathe. Improper uid
levels or the wrong tire ination can increase the level of
emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good condition,
be sure to maintain your vehicle properly.
Using the Maintenance Schedule
We at Saturn want to help you keep your vehicle in good
working condition. But we do not know exactly how
you will drive it. You may drive very short distances only
a few times a week. Or you may drive long distances
all the time in very hot, dusty weather. You may
use your vehicle in making deliveries. Or you may drive
it to work, to do errands, or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your Saturn retailer.
This schedule is for vehicles that:
carry passengers and cargo within recommended
limits. You will nd these limits on the tire and
loading information label. SeeLoading Your Vehicle
on page 4-31.
are driven on reasonable road surfaces within legal
driving limits.
use the recommended fuel. SeeGasoline Octane
on page 5-5.
6-2
ProCarManuals.com