brake SATURN RELAY 2005 Service Manual

Total Weight on Your Vehicle’s Tires
Be sure your vehicle’s tires are inated to the upper limit
for cold tires. You will nd these numbers on the
Certication/Tire label at the rear edge of the driver’s
door or seeLoading Your Vehicle on page 4-31.
Then be sure you do not go over the GVW limit for your
vehicle, including the weight of the trailer tongue.
Hitches
It is important to have the correct hitch equipment.
Crosswinds, large trucks going by, and rough roads are
a few reasons why you will need the right hitch. Here
are some rules to follow:
The bumpers on your vehicle are not intended for
hitches. Do not attach rental hitches or other
bumper-type hitches to them. Use only a
frame-mounted hitch that does not attach to the
bumper.
If you will be pulling a trailer that, when loaded, will
weigh more than 2,000 lbs (900 kg), be sure to use
a properly mounted weight-carrying hitch and
sway control of the proper size. This equipment is
very important for proper vehicle loading and
good handling when you are driving.
Will you have to make any holes in the body of
your vehicle when you install a trailer hitch?If you do, remember to seal the holes later when
you remove the hitch. If you do not seal them,
deadly carbon monoxide (CO) from your exhaust
can get into your vehicle. SeeEngine Exhaust
on page 2-40. Dirt and water can, too.
Safety Chains
You should always attach chains between your vehicle
and your trailer. Cross the safety chains under the
tongue of the trailer to help prevent the tongue from
contacting the road if it becomes separated from
the hitch. Instructions about safety chains may be
provided by the hitch manufacturer or by the trailer
manufacturer. Follow the manufacturer’s
recommendation for attaching safety chains and do not
attach them to the bumper. Always leave just enough
slack so you can turn with your rig. Never allow
safety chains to drag on the ground.
Trailer Brakes
If your trailer weighs more than 1,000 lbs (450 kg)
loaded, then it needs its own brakes – and they must be
adequate. Be sure to read and follow the instructions
for the trailer brakes so you will be able to install, adjust,
and maintain them properly.
Because your vehicle may have anti-lock brakes, do not
try to tap into your vehicle’s brake system. If you do,
both brake systems will not work well, or at all.
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Driving with a Trailer
{CAUTION:
If you have a rear-most window open and you
pull a trailer with your vehicle, carbon
monoxide (CO) could come into your vehicle.
You cannot see or smell CO. It can cause
unconsciousness or death. SeeEngine
Exhaust on page 2-40. To maximize your safety
when towing a trailer:
Have your exhaust system inspected for
leaks, and make necessary repairs before
starting on your trip.
Keep the rear-most windows closed.
If exhaust does come into your vehicle
through a window in the rear or another
opening, drive with your front, main
heating or cooling system on and with the
fan on any speed. This will bring fresh,
outside air into your vehicle. Do not use
the climate control setting for maximum air
because it only recirculates the air inside
your vehicle. SeeClimate Control System
on page 3-24.Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you will want to
get to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
Before you start, check all trailer hitch parts and
attachments, safety chains, electrical connector, lamps,
tires, and mirror adjustment. If the trailer has electric
brakes, start your vehicle and trailer moving and
then apply the trailer brake controller by hand to be sure
the brakes are working. This lets you check your
electrical connection at the same time.
During your trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer
brakes are still working.
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Driving on Grades
Reduce speed and shift to a lower gear before you start
down a long or steep downgrade. If you do not shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
If you are towing a trailer that weighs more than
1,000 lbs (450 kg), you may prefer to drive in THIRD (3)
instead of AUTOMATIC OVERDRIVE (D) or, as you
need to, a lower gear. This will minimize heat build-up
and extend the life of your transaxle.
Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, do the
following:
1. Apply your regular brakes, but do not shift into
PARK (P).
2. Have someone place chocks under the trailer
wheels.
3. When the wheel 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).
5. Release the regular brakes.
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When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you do the following:
Start your engine.
Shift into a gear.
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 are
pulling a trailer. See the Maintenance Schedule for
more on this. Things that are especially important in
trailer operation are automatic transaxle uid, engine oil,
belts, cooling system, and brake system. Each of
these is covered in this manual, and the Index will help
you nd them quickly. If you are trailering, it is a
good idea to review these sections before you start
your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Trailer Wiring Harness
Your vehicle has a trailer wiring harness located at the
rear of your vehicle. To use the trailer wiring harness,
you need a converter kit. Contact your retailer for more
information.
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Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling the Tank..............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Oil Life System..................................5-16
Engine Air Cleaner/Filter................................5-18
Automatic Transaxle Fluid..............................5-19
Engine Coolant.............................................5-22
Radiator Pressure Cap..................................5-25
Engine Overheating.......................................5-25
Overheated Engine Protection
Operating Mode........................................5-27
Cooling System............................................5-28
Power Steering Fluid.....................................5-34Windshield Washer Fluid................................5-35
Brakes........................................................5-36
Battery........................................................5-39
Jump Starting...............................................5-40
All-Wheel Drive..............................................5-45
Bulb Replacement..........................................5-47
Halogen Bulbs..............................................5-47
Headlamps and Sidemarker Lamps.................5-47
Front Turn Signal, Parking and Daytime
Running Lamps (DRL)................................5-49
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-49
Replacement Bulbs.......................................5-50
Windshield Wiper Blade Replacement..............5-51
Tires..............................................................5-52
Tire Sidewall Labelling...................................5-53
Tire Terminology and Denitions.....................5-55
Ination - Tire Pressure.................................5-58
Tire Inspection and Rotation...........................5-59
When It Is Time for New Tires.......................5-60
Buying New Tires.........................................5-61
Uniform Tire Quality Grading..........................5-62
Wheel Alignment and Tire Balance..................5-63
Wheel Replacement......................................5-64
Section 5 Service and Appearance Care
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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.
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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.
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Checking the Fluid Level
Prepare your vehicle as follows:
1. Park your vehicle on a level place. Keep the engine
running.
2. With the parking brake applied, place the shift lever
in PARK (P).
3. With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position
the shift lever in PARK (P).
4. Let the engine run at idle for three to ve minutes.
Then, without shutting off the engine, follow these steps:
1. Pull out the dipstick and wipe it with a clean rag or
paper towel.
The automatic transaxle dipstick is located toward
the back of the engine compartment, next to
the brake master cylinder reservoir. The dipstick
handle is a red loop. SeeEngine Compartment
Overview on page 5-12for more information
on location.2. Push it back in all the way, wait three seconds, and
then pull it back out again.
3. Check both sides of the dipstick, and read the
lower level. The uid level must be in the
cross-hatched area.
4. If the uid level is in the acceptable range, push the
dipstick back in all the way.
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Brakes
Brake Fluid
Your 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 rst is that the
brake uid goes down to an acceptable level during
normal brake lining wear. When new linings are put in,
the uid level goes back up. The other reason is
that uid is leaking out of the brake system. If it is, you
should have your brake system xed, since a leak
means that sooner or later your brakes will not work
well, or will not work at all.So, it is not a good idea to top off your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add or remove brake uid, as necessary, only when
work is done on the brake hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake uid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-35.
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What to Add
When you do need brake uid, use only DOT-3 brake
uid. Use new brake uid from a sealed container
only. SeeRecommended Fluids and Lubricants on
page 6-12.
Always clean the brake uid reservoir cap and the area
around the cap before removing it. This will help
keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or
they may not even work at all. This could
cause a crash. Always use the proper
brake uid.Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system
parts so badly that they will have to be replaced.
Do not let someone put in the wrong kind of
uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeAppearance
Care on page 5-87.
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