fuel SATURN RELAY 2006 Service Manual

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 4-33.
are driven on reasonable road surfaces within legal
driving limits.
use the recommended fuel. SeeGasoline Octane
on page 5-4.
6-2
ProCarManuals.com

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 5-20.•••
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).•
6-6
ProCarManuals.com

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.
6-7
ProCarManuals.com

(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 5-23 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.
(l)If you drive regularly under dusty conditions, the lter
may require replacement more often.
(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 6-11.
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 5-15for 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.
6-8
ProCarManuals.com

Usage Fluid/Lubricant
Power Steering
SystemPower Steering Fluid
(Saturn Part No. 21007583 or
GM Part No. U.S. 89021184, in
Canada 89021186).
Automatic
TransaxleDEXRON
®-VI Automatic
Transmission Fluid.
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.
Carrier
Assembly –
Differential
(Rear Drive
Module) and
Transfer Case
(Power
Transfer Unit)VERSATRAK
®Fluid
(GM Part No. U.S. 12378514, in
Canada 88901045).
Usage Fluid/Lubricant
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.
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).
6-12
ProCarManuals.com

GM Mobility Reimbursement
Program
This program, available to qualied applicants, can
reimburse you up to $1,000 toward eligible aftermarket
driver or passenger adaptive equipment you may
require for your vehicle such as hand controls,
wheelchair/scooter lifts, etc.
The offer is available for a limited period of time from
the date of vehicle purchase/lease.
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. call1-800-553-6000
(TTY: 1-800-833-6000).
For vehicles purchased in Canada call1-800-268-6800.
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).
7-5
ProCarManuals.com

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).
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. If your
vehicle is equipped with StabiliTrak
®, steering
performance, including yaw rate, steering wheel angle,
and lateral acceleration, is also recorded. 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.
7-7
ProCarManuals.com

A
Accessories and Modications............................ 5-3
Accessory Inator...........................................5-68
Accessory Power Outlet(s)...............................3-24
Adding Equipment to Your Airbag-Equipped
Vehicle.......................................................1-78
Additives, Fuel................................................. 5-5
Add-On Electrical Equipment............................5-96
Air Cleaner/Filter, Engine.................................5-20
Air Conditioning..............................................3-26
Airbag
Passenger Status Indicator...........................3-38
Readiness Light..........................................3-37
Airbag Sensing and Diagnostic Module (SDM)...... 7-7
Airbag System................................................1-65
Adding Equipment to Your Airbag-Equipped
Vehicle...................................................1-78
How Does an Airbag Restrain?......................1-72
Passenger Sensing System...........................1-74
Servicing Your Airbag-Equipped Vehicle..........1-78
What Makes an Airbag Inate?......................1-72
What Will You See After an Airbag Inates?....1-73
When Should an Airbag Inate?....................1-71
Where Are the Airbags?...............................1-68
All-Wheel Drive...............................................5-46
All-Wheel-Drive (AWD) System.........................4-12Antenna, Fixed Mast......................................3-119
Antenna, XM™ Satellite Radio Antenna
System.....................................................3-120
Anti-Lock Brake System (ABS)........................... 4-7
Anti-Lock Brake, System Warning Light..............3-41
Appearance Care
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
Audio System(s).............................................3-81
Audio Steering Wheel Controls....................3-117
Care of Your CD and DVD Player................3-119
1
ProCarManuals.com

Audio System(s) (cont.)
Care of Your CDs and DVDs.......................3-119
Chime Level Adjustment.............................3-120
Fixed Mast Antenna...................................3-119
Navigation/Radio System, see Navigation
Manual.................................................3-102
Radio with CD............................................3-83
Rear Seat Audio (RSA)...............................3-115
Setting the Time..........................................3-82
Theft-Deterrent Feature...............................3-117
Understanding Radio Reception...................3-118
XM™ Satellite Radio Antenna System...........3-120
Automatic Door Lock.......................................2-14
Automatic Transaxle
Fluid..........................................................5-21
Operation...................................................2-36
B
Battery..........................................................5-40
Run-Down Protection...................................3-20
Before Leaving on a Long Trip.........................4-24
Brake
Anti-Lock Brake System (ABS)........................ 4-7
Emergencies................................................ 4-8
Parking......................................................2-39
System Warning Light..................................3-40Brakes..........................................................5-37
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-33
Bucket Seats, Rear........................................... 1-7
Bulb Replacement...........................................5-48
Front Turn Signal, Parking and Daytime
Running Lamps........................................5-50
Halogen Bulbs............................................5-48
Replacement Bulbs......................................5-51
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-50
Buying New Tires...........................................5-62
C
California Fuel.................................................. 5-5
California Proposition 65 Warning....................... 5-3
Canadian Owners................................................ ii
Capacities and Specications..........................5-103
Captain Chairs, Rear.......................................1-14
Carbon Monoxide...................2-24, 2-42, 4-27, 4-40
Care of
Safety Belts................................................5-91
Your CD and DVD Player...........................3-119
Your CDs and DVDs..................................3-119
2
ProCarManuals.com

Engine
Air Cleaner/Filter.........................................5-20
Battery.......................................................5-40
Check and Service Engine Soon Light............3-43
Coolant......................................................5-23
Coolant Heater............................................2-35
Coolant Temperature Gage...........................3-42
Engine Compartment Overview......................5-12
Exhaust.....................................................2-42
Oil .............................................................5-15
Oil Life System...........................................5-18
Overheated Protection Operating Mode...........5-28
Overheating................................................5-26
Starting......................................................2-34
Entry Lighting.................................................3-18
Event Data Recorders (EDR)............................. 7-7
Exit Lighting...................................................3-19
Extender, Safety Belt.......................................1-42
Exterior Lamps...............................................3-15
F
Filter
Engine Air Cleaner......................................5-20
Finish Damage...............................................5-94
Fixed Mast Antenna.......................................3-119Flash-to-Pass................................................... 3-8
Flat Tire........................................................5-70
Flat Tire, Changing.........................................5-71
Flat Tire, Storing.............................................5-83
Fluid
Automatic Transaxle.....................................5-21
Power Steering...........................................5-35
Windshield Washer......................................5-36
Folding Tray...................................................2-53
Front Console Storage Area.............................2-52
Front Reading Lamps......................................3-20
Fuel............................................................... 5-4
Additives...................................................... 5-5
California Fuel.............................................. 5-5
Filling a Portable Fuel Container..................... 5-9
Filling Your Tank........................................... 5-6
Fuels in Foreign Countries.............................. 5-6
Gage.........................................................3-48
Gasoline Octane........................................... 5-4
Gasoline Specications.................................. 5-5
Low Warning Light.......................................3-48
Fuses
Fuses and Circuit Breakers...........................5-97
Instrument Panel Fuse Block.........................5-98
Underhood Fuse Block...............................5-100
Windshield Wiper.........................................5-97
5
ProCarManuals.com