fuel SATURN RELAY 2005 Service Manual

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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Maintenance Footnotes
#Lubricate the suspension, steering linkage, transaxle
shift linkage, and the underbody contact points and
linkage.
(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 other brake parts, including calipers,
parking brake, etc. Check parking brake adjustment.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose, or missing parts,
signs of wear, or lack of lubrication. Inspect power
steering lines and hoses for proper hook-up, binding,
leaks, cracks, chang, etc.
(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, hood latch
assemblies, secondary latches, pivots, spring anchor
and release pawl, hood and door hinges, rear folding
seats, liftgate hinges, fuel door hinge, power sliding door
cable, and sliding door track(s). 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)If you drive regularly under dusty conditions, inspect
the lter at each engine oil change.
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(h)Change automatic transaxle uid and lter if the
vehicle is mainly driven under one or more of these
conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police, or delivery
service.
(i)Drain, ush, and rell cooling system. See Engine
Coolant on page 5-22 for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap, and ller neck.
Pressure test the cooling system and pressure cap.
(j)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.
(k)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired
and the uid level checked. Add uid if needed.
(m)Visually inspect belt for fraying, excessive cracks, or
obvious damage. Replace belt if necessary.Owner Checks and Services
These owner checks and services should be performed
at the intervals specied to help ensure the safety,
dependability and emission control performance of your
vehicle. Your Saturn retailer can assist you with these
checks and services.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-12.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
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Usage Fluid/Lubricant
Carrier
Assembly —
Differential
(Rear Drive
Module) and
Transfer
Case (Power
Transfer Unit)VERSATRAK
®Fluid
(GM Part No. U.S. 12378514,
in Canada 88901045).
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.
Usage Fluid/Lubricant
Hood and Door
Hinges, Rear
Folding Seat,
Fuel Door
Hinge, Liftgate
Hinges and
Power Sliding
Door CableMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Sliding Door
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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For more details, or to determine your vehicle’s
eligibility, visit your Saturn retailer or call the Saturn
Customer Assistance Center at 1-800-553-6000. Text
telephone (TTY) users, call 1-800-833-6000.
In Canada, customers may call the Saturn Customer
Communication Centre at 1-800-263-1999. TTY users in
Canada may call 1-800-263-3830.
Roadside Assistance Program
For vehicles purchased in the U.S. call 1-800-553-6000
(TTY: 1-800-833-6000).
For vehicles purchased in Canada call 1-800-268-6800.
As the proud owner of a new Saturn vehicle, you are
automatically enrolled in the Saturn Roadside
Assistance Program. This value-added service is
intended to provide you with peace of mind as you drive
in the city or travel the open road. Saturn’s Roadside
Assistance toll-free number is staffed by courteous and
capable Roadside Assistance Representatives who
are available 24 hours a day, 365 days a year.We will provide the following services during the
Bumper-to-Bumper warranty period at no expense
to you:
Fuel Delivery:Delivery of enough fuel
($5 maximum) for the customer to get to the
nearest service station.
Lock-out Service (identication required):
Replacement keys or locksmith service will
be covered at no charge if you are unable to gain
entry into your vehicle. Delivery of the replacement
key will be covered within 10 miles (16 km).
Emergency Tow:Tow to the nearest Saturn
retailer for warranty service or in the event of
a vehicle-disabling accident. Assistance provided
when the vehicle is mired in sand, mud, or snow.
Flat Tire Change:Installation of a spare tire will be
covered at no charge. (The customer is responsible
for the repair or replacement of the tire if not
covered by a warrantable failure.)
Jump Start:No-start occurrences which require a
battery jump start will be covered at no charge.
Saturn Retailer Locator Service
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In many instances, mechanical failures are covered
under Saturn’s Bumper-to-Bumper warranty. However,
when other services are utilized, our Roadside
Assistance Representatives will explain any payment
obligations you might incur.
For prompt and efficient assistance when calling, please
provide the following to the Roadside Assistance
Representatives:
Your name, home address, and home telephone
number
Telephone number of your location
Location of the vehicle
Model, year, color, and license plate number
Mileage, Vehicle Identication Number and delivery
date of the vehicle
Description of the problem
While we hope you never have the occasion to use our
service, it is added security while traveling for you
and your family. Remember we are only a phone call
away. Saturn Roadside Assistance: 1-800-553-6000;
text telephone (TTY) users, call 1-800-833-6000.
Saturn reserves the right to limit services or
reimbursement to an owner or driver when, in Saturn’s
judgment, the claims become excessive in frequency
or type of occurrence.Roadside Assistance is not part of or included in the
coverage provided by the New Vehicle Limited Warranty.
Saturn reserves the right to make any changes or
discontinue the Roadside Assistance program at any
time without notication.
Canadian Roadside Assistance
Vehicles purchased in Canada have an extensive Saturn
Roadside Assistance program accessible from anywhere
in Canada or the United States. Please refer to the
Warranty and Owner Assistance Information book.
Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s performance.
Your vehicle uses on-board vehicle computers to monitor
emission control components to optimize fuel economy,
to monitor conditions for airbag deployment and, if so
equipped, to provide anti-lock braking and to help the
driver control the vehicle in difficult driving situations.
Some information may be stored during regular
operations to facilitate repair of detected malfunctions;
other information is stored only in a crash event by
computer systems, such as those commonly called event
data recorders (EDR).
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A
Accessory Inator...........................................5-66
Accessory Power Outlets.................................3-22
Adding Equipment to Your Airbag-Equipped
Vehicle.......................................................1-78
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-97
Air Cleaner/Filter, Engine.................................5-18
Air Conditioning..............................................3-24
Airbag
Passenger Status Indicator...........................3-33
Readiness Light..........................................3-32
Airbag Sensing and Diagnostic Module (SDM)...... 7-6
Airbag System................................................1-64
Adding Equipment to Your Airbag-Equipped
Vehicle...................................................1-78
How Does an Airbag Restrain?......................1-71
Passenger Sensing System...........................1-74
Servicing Your Airbag-Equipped Vehicle..........1-78
What Makes an Airbag Inate?......................1-71
What Will You See After an Airbag Inates?....1-72
When Should an Airbag Inate?....................1-69
Where Are the Airbags?...............................1-67
All-Wheel Drive...............................................5-45
All-Wheel Drive (AWD) System.........................2-36All-Wheel-Drive (AWD) System.........................4-11
Antenna, Fixed Mast......................................3-111
Antenna, XM™ Satellite Radio
Antenna System........................................3-111
Anti-Lock Brake System (ABS)........................... 4-6
Anti-Lock Brake, System Warning Light..............3-36
Appearance Care............................................5-87
Aluminum Wheels........................................5-93
Care of Safety Belts....................................5-91
Chemical Paint Spotting...............................5-94
Cleaning Exterior Lamps/Lenses....................5-91
Cleaning the Inside of Your Vehicle................5-88
Fabric/Carpet..............................................5-89
Finish Care.................................................5-92
Finish Damage............................................5-94
Instrument Panel, Vinyl, and Other Plastic
Surfaces.................................................5-90
Leather......................................................5-90
Sheet Metal Damage...................................5-94
Tires..........................................................5-93
Underbody Maintenance...............................5-94
Vehicle Care/Appearance Materials................5-95
Washing Your Vehicle...................................5-91
Weatherstrips..............................................5-91
Windshield, Backglass, and Wiper Blades.......5-92
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Audio System(s).............................................3-72
Audio Steering Wheel Controls....................3-109
Care of Your CD and DVD Player................3-111
Care of Your CDs and DVDs.......................3-111
Fixed Mast Antenna...................................3-111
Radio with CD............................................3-73
Rear Seat Audio (RSA)...............................3-106
Setting the Time..........................................3-72
Theft-Deterrent Feature...............................3-109
Understanding Radio Reception...................3-110
XM™ Satellite Radio Antenna System...........3-111
Automatic Door Locks.....................................2-13
Automatic Transaxle
Fluid..........................................................5-19
Operation...................................................2-33
B
Battery..........................................................5-39
Run-Down Protection...................................3-19
Before Leaving on a Long Trip.........................4-23
Brake
Anti-Lock Brake System (ABS)........................ 4-6
Emergencies................................................ 4-8
Parking......................................................2-37
System Warning Light..................................3-35
Brakes..........................................................5-36
Braking........................................................... 4-5
Braking in Emergencies..................................... 4-8Break-In, New Vehicle.....................................2-30
Bucket Seats, Rear........................................... 1-8
Bulb Replacement...........................................5-47
Front Turn Signal, Parking and Daytime
Running Lamps........................................5-49
Halogen Bulbs............................................5-47
Replacement Bulbs......................................5-50
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-49
Buying New Tires...........................................5-61
C
California Fuel.................................................. 5-6
Canadian Owners................................................ ii
Capacities and Specications..........................5-103
Captain Chairs, Rear.......................................1-14
Carbon Monoxide...................2-21, 2-40, 4-26, 4-38
Care of
Safety Belts................................................5-91
Your CD and DVD Player...........................3-111
Your CDs and DVDs..................................3-111
Cargo Lamp...................................................3-19
Chains, Tire...................................................5-65
Charging System Light....................................3-35
Check
Engine Light...............................................3-38
Checking Things Under the Hood......................5-10
Chemical Paint Spotting...................................5-94
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Engine (cont.)
Coolant Temperature Gage...........................3-37
Engine Compartment Overview......................5-12
Exhaust.....................................................2-40
Oil .............................................................5-13
Oil Life System...........................................5-16
Overheated Protection Operating Mode...........5-27
Overheating................................................5-25
Starting......................................................2-31
Entry Lighting.................................................3-17
Event Data Recorders (EDR)............................. 7-6
Exit Lighting...................................................3-18
Extender, Safety Belt.......................................1-42
Exterior Lamps...............................................3-14
F
Filter
Engine Air Cleaner......................................5-18
Finish Damage...............................................5-94
Fixed Mast Antenna.......................................3-111
Flash-to-Pass................................................... 3-9
Flat Tire........................................................5-68
Flat Tire, Changing.........................................5-69
Flat Tire, Storing.............................................5-82
Flip and Fold Rear Seats.................................. 1-7Fluid
Automatic Transaxle.....................................5-19
Power Steering...........................................5-34
Windshield Washer......................................5-35
Folding Tray...................................................2-51
Front Console Storage Area.............................2-51
Front Reading Lamps......................................3-18
Fuel............................................................... 5-5
Additives...................................................... 5-6
California Fuel.............................................. 5-6
Filling a Portable Fuel Container....................5-10
Filling Your Tank........................................... 5-8
Fuels in Foreign Countries.............................. 5-7
Gage.........................................................3-42
Gasoline Octane........................................... 5-5
Gasoline Specications.................................. 5-5
Low Warning Light.......................................3-42
Fuses
Fuses and Circuit Breakers...........................5-98
Instrument Panel Fuse Block.........................5-98
Underhood Fuse Block...............................5-100
Windshield Wiper.........................................5-97
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G
Gage
Engine Coolant Temperature.........................3-37
Fuel..........................................................3-42
Speedometer..............................................3-31
Tachometer.................................................3-31
Garage Door Opener.......................................2-44
Gasoline
Octane........................................................ 5-5
Specications............................................... 5-5
Glove Box.....................................................2-49
GM Mobility Reimbursement Program.................. 7-4
H
Hazard Warning Flashers................................... 3-6
Head Restraints............................................... 1-6
Headlamp Wiring............................................5-97
Headlamps
Bulb Replacement.......................................5-47
Daytime Running Lamps/Automatic
Headlamp System....................................3-15
Flash-to-Pass............................................... 3-9Headlamps (cont.)
Front Turn Signal, Parking and Daytime
Running Lamps........................................5-49
Halogen Bulbs............................................5-47
Headlamps and Sidemarker Lamps................5-47
High/Low Beam Changer................................ 3-8
On Reminder..............................................3-15
Wiper Activated...........................................3-14
Headlamps and Sidemarker Lamps...................5-47
Heated Seats................................................... 1-3
Heater...........................................................3-24
Hideaway Rear Storage Bins............................2-54
Highbeam On Light.........................................3-41
Highway Hypnosis...........................................4-24
Hill and Mountain Roads..................................4-24
HomeLink
®Wireless Control System.................2-44
HomeLink®Wireless Control System
Operation...................................................2-45
Hood
Checking Things Under................................5-10
Release.....................................................5-11
Horn............................................................... 3-6
How to Use This Manual...................................... ii
How to Wear Safety Belts Properly...................1-27
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