brake SATURN RELAY 2005 Repair Manual

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
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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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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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Engine Coolant Level Check
Check the engine coolant level and add
DEX-COOL®coolant mixture if necessary. SeeEngine
Coolant on page 5-22for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer tank and add the proper uid if necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your vehicle’s tires and make sure they
are inated to the correct pressures. Do not forget to
check the spare tire. SeeTires on page 5-52for further
details. Check to make sure the spare tire is stored
securely. SeeChanging a Flat Tire on page 5-69.
Tire Wear Inspection
Tire rotation may be required for high mileage highway
drivers prior to the Engine Oil Life System service
notication. Check the tires for wear and, if necessary,
rotate the tires. SeeTire Inspection and Rotation on
page 5-59.
At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-37.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The vehicle
should start only in PARK (P) or NEUTRAL (N). If
the vehicle starts in any other position, contact your
Saturn retailer for service.
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Automatic Transaxle Shift Lock Control
System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle. It should be parked on a level
surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-37.
Be ready to apply the regular brake immediately if
the vehicle begins to move.
3. With the engine off, turn the ignition to RUN, but do
not start the engine. Without applying the regular
brake, try to move the shift lever out of PARK (P)
with normal effort. If the shift lever moves out
of PARK (P), contact your Saturn retailer for service.
Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition to LOCK in each shift lever position.
The ignition should turn to LOCK only when the
shift lever is in PARK (P).
The key should come out only in LOCK.
Contact your Saturn retailer if service is required.
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Parking Brake and Automatic Transaxle
Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake, set the
parking brake.
To check the parking brake’s holding ability: With
the engine running and transaxle in NEUTRAL (N),
slowly remove foot pressure from the regular
brake pedal. Do this until the vehicle is held by the
parking brake only.
To check the PARK (P) mechanism’s holding
ability: With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Contact your Saturn retailer if service is required.
Underbody Flushing Service
At least every spring, use plain water to ush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
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Recommended Fluids and
Lubricants
Fluids and lubricants identied below by name, part
number, or specication may be obtained from
your retailer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certied for Gasoline Engines
starburst symbol. GM Goodwrench
®
oil meets all the requirements for
your vehicle. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant on
page 5-22.
Usage Fluid/Lubricant
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake uid.
Windshield
WasherGM Optikleen
®Washer Solvent.
Power Steering
SystemPower Steering Fluid
(Saturn Part No. 21007583 or
GM Part No. U.S. 89021184, in
Canada 89021186).
Automatic
TransaxleDEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specication”
on the label.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474.
Chassis
LubricationChassis Lubricant
(GM Part No. U.S. 12377985, in
Canada 88901242) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
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In a crash event, computer systems, such as the Airbag
Sensing and Diagnostic Module (SDM) in your vehicle
may record information about the condition of the vehicle
and how it was operated, such as data related to
engine speed, brake application, throttle position, vehicle
speed, safety belt usage, airbag readiness, airbag
performance, and the severity of a collision. This
information has been used to improve vehicle crash
performance and may be used to improve crash
performance of future vehicles and driving safety. Unlike
the data recorders on many airplanes, these on-board
systems do not record sounds, such as conversation of
vehicle occupants.
To read this information, special equipment is needed
and access to the vehicle or the device that stores
the data is required. GM will not access information
about a crash event or share it with others other than:
with the consent of the vehicle owner or, if the
vehicle is leased, with the consent of the lessee,
in response to an official request of police or similar
government office,
as part of GM’s defense of litigation through the
discovery process, or
as required by law.In addition, once GM collects or receives data, GM may:
use the data for GM research needs,
make it available for research where appropriate
condentiality is to be maintained and need is
shown, or
share summary data which is not tied to a specic
vehicle with non-GM organizations for research
purposes.
Others, such as law enforcement, may have access to
the special equipment that can read the information
if they have access to the vehicle or the device
that stores the data.
If your vehicle is equipped with OnStar
®, please check
the OnStar®subscription service agreement or
manual for information on its operations and data
collection.
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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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