service SATURN RELAY 2006 Workshop Manual

Buying New Tires.........................................5-62
Different Size Tires and Wheels......................5-63
Uniform Tire Quality Grading..........................5-64
Wheel Alignment and Tire Balance..................5-65
Wheel Replacement......................................5-65
Tire Chains..................................................5-67
Accessory Inator.........................................5-68
If a Tire Goes Flat........................................5-70
Changing a Flat Tire.....................................5-71
Removing the Spare Tire and Tools................5-72
Removing the Flat Tire and Installing the
Spare Tire................................................5-75
Secondary Latch System...............................5-81
Storing a Flat or Spare Tire and Tools............5-83
Compact Spare Tire......................................5-87
Appearance Care............................................5-88
Cleaning the Inside of Your Vehicle.................5-88
Fabric/Carpet...............................................5-89
Leather.......................................................5-90
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-90
Care of Safety Belts......................................5-91
Weatherstrips...............................................5-91
Washing Your Vehicle...................................5-91Cleaning Exterior Lamps/Lenses.....................5-91
Finish Care..................................................5-92
Windshield, Backglass, and Wiper Blades.........5-92
Aluminum Wheels.........................................5-93
Tires...........................................................5-93
Sheet Metal Damage.....................................5-94
Finish Damage.............................................5-94
Underbody Maintenance................................5-94
Chemical Paint Spotting.................................5-94
Vehicle Care/Appearance Materials..................5-95
Vehicle Identication......................................5-96
Vehicle Identication Number (VIN).................5-96
Service Parts Identication Label.....................5-96
Electrical System............................................5-96
Add-On Electrical Equipment..........................5-96
Headlamp Wiring..........................................5-97
Windshield Wiper Fuses................................5-97
Power Windows and Other Power Options.......5-97
Fuses and Circuit Breakers............................5-97
Instrument Panel Fuse Block..........................5-98
Underhood Fuse Block................................5-100
Capacities and Specications........................5-103
Section 5 Service and Appearance Care
5-2
ProCarManuals.com

Service
Your Saturn retailer knows your vehicle best and wants
you to be happy with it. We hope you will go to your
retailer for all your service needs. You will get genuine
Saturn parts and Saturn-trained and supported
service people.
We hope you will want to keep your Saturn vehicle all
Saturn.
Genuine Saturn parts have one of these marks.
Accessories and Modications
When you add non-Saturn accessories to your vehicle
they can affect your vehicle’s performance and
safety, including such things as, braking, stability, ride
and handling, emissions systems, aerodynamics,
durability, and electronic systems like antilock brakes,
traction control and stability control. Some of these
accessories may even cause malfunction or damage not
covered by warranty.
Saturn Accessories are designed to complement and
function with other systems on your vehicle. Your Saturn
retailer can accessorize your vehicle using genuine
Saturn Accessories. When you go to your Saturn retailer
and ask for Saturn Accessories, you will know that
Saturn-trained and supported service technicians will
perform the work using genuine Saturn Accessories.
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3
ProCarManuals.com

Doing Your Own Service Work
{CAUTION:
You can be injured and your vehicle could be
damaged if you try to do service work on a
vehicle without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts,
and tools before you attempt any vehicle
maintenance task.
Be sure to use the proper nuts, bolts, and
other fasteners. English and metric
fasteners can be easily confused. If you
use the wrong fasteners, parts can later
break or fall off. You could be hurt.
If you want to do some of your own service work, you
will want to use the proper service manual. It tells
you much more about how to service your vehicle than
this manual can. To order the proper service manual,
seeService Publications Ordering Information on
page 7-12.
Your vehicle has an airbag system. Before attempting to
do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-78.You should keep a record with all parts receipts and list
the mileage and the date of any service work you
perform. SeeMaintenance Record on page 6-14.
Adding Equipment to the Outside of
Your Vehicle
Things you might add to the outside of your vehicle can
affect the airow around it. This may cause wind
noise and affect windshield washer performance. Check
with your retailer before adding equipment to the
outside of your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane
rating of 87 or higher. If the octane rating is less than 87,
you may notice an audible knocking noise when you
drive, commonly referred to as spark knock. If this
occurs, use a gasoline rated at 87 octane or higher as
soon as possible. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking, your
engine needs service.
5-4
ProCarManuals.com

Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese tricarbonyl
(MMT); ask the attendant where you buy gasoline
whether the fuel contains MMT. General Motors
recommends against the use of such gasolines. Fuels
containing MMT can reduce the life of spark plugs
and the performance of the emission control system may
be affected. The malfunction indicator lamp may turn
on. If this occurs, return to your authorized Saturn
retailer for service.
Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to
you and others, read and follow all the
instructions on the pump island. Turn off your
engine when you are refueling. Do not smoke
if you are near fuel or refueling your vehicle.
Keep sparks, ames, and smoking materials
away from fuel. Do not leave the fuel pump
unattended when refueling your vehicle — this
is against the law in some places. Keep
children away from the fuel pump; never let
children pump fuel.
5-6
ProCarManuals.com

How to Reset the Engine Oil Life
System
The Engine Oil Life System calculates when to change
your engine oil and lter based on vehicle use.
Anytime your oil is changed, reset the system so it can
calculate when the next oil change is required. If a
situation occurs where you change your oil prior to a
CHANGE OIL SOON message being turned on,
reset the system.
1. With the ignition key in RUN but the engine off,
repeatedly push the set/reset button until OIL is
displayed on the Driver Information Center (DIC).
2. Once OIL is displayed, push and hold the set/reset
button for ve seconds. The number will disappear
and be replaced by 100 (indicating 100% oil life
remaining).
3. Turn the key to LOCK.
If the CHANGE OIL SOON message comes back on
when you start your vehicle, the engine oil life system
has not reset. Repeat the procedure.
What to Do with Used Oil
Used engine oil contains certain elements that may be
unhealthy for your skin and could even cause cancer.
Do not let used oil stay on your skin for very long. Clean
your skin and nails with soap and water, or a good
hand cleaner. Wash or properly dispose of clothing or
rags containing used engine oil. See the manufacturer’s
warnings about the use and disposal of oil products.
Used oil can be a threat to the environment. If you
change your own oil, be sure to drain all the oil from the
lter before disposal. Never dispose of oil by putting it
in the trash, pouring it on the ground, into sewers, or into
streams or bodies of water. Instead, recycle it by
taking it to a place that collects used oil. If you have a
problem properly disposing of your used oil, ask
your retailer, a service station, or a local recycling center
for help.
5-19
ProCarManuals.com

{CAUTION:
Operating the engine with the air cleaner/lter
off can cause you or others to be burned. The
air cleaner not only cleans the air; it helps to
stop ames if the engine backres. If it is not
there and the engine backres, you could be
burned. Do not drive with it off, and be
careful working on the engine with the air
cleaner/lter off.
Notice:If the air cleaner/lter is off, a backre can
cause a damaging engine re. And, dirt can
easily get into your engine, which will damage it.
Always have the air cleaner/lter in place when you
are driving.
Automatic Transaxle Fluid
When to Check and Change Automatic
Transaxle Fluid
A good time to check your automatic transaxle uid
level is when the engine oil is changed.
Change the uid and lter at the intervals listed in
Additional Required Services on page 6-6, and be sure
to use the transaxle uid listed inRecommended
Fluids and Lubricants on page 6-11.
How to Check Automatic Transaxle
Fluid
Because this operation can be a little difficult, you may
choose to have this done at your retailer’s service
department.
If you do it yourself, be sure to follow all the instructions
here, or you could get a false reading on the dipstick.
Notice:Too much or too little uid can damage the
transaxle. Too much can mean that some of the uid
could come out and fall on hot engine or exhaust
system parts, starting a re. Too little uid could
cause the transaxle to overheat. Be sure to get an
accurate reading if you check the transaxle uid.
5-21
ProCarManuals.com

How to Add Automatic Transaxle Fluid
Refer to the Maintenance Schedule to determine
what kind of transaxle uid to use. SeeRecommended
Fluids and Lubricants on page 6-11.
If the uid level is low, add only enough of the proper
uid to bring the level into the cross-hatched area on the
dipstick.
1. Pull out the dipstick.
2. Using a long-neck funnel, add enough uid at the
dipstick hole to bring it to the proper level.
It does not take much uid, generally less than
one pint (0.5 L). Do not overll.
Notice:Use of the incorrect automatic transaxle
uid may damage your vehicle, and the damages
may not be covered by your warranty. Always
use the automatic transaxle uid listed in
Recommended Fluids and Lubricants on page 6-11.
3. After adding uid, recheck the uid level as
described under “How to Check Automatic
Transaxle Fluid,” earlier in this section.
4. When the correct uid level is obtained, push the
dipstick back in all the way.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is designed
to remain in your vehicle for ve years or 150,000 miles
(240 000 km), whichever occurs rst, if you add only
DEX-COOL
®extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem
with engine overheating, seeEngine Overheating on
page 5-26.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning messages and gages work as they
should.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core, or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at the rst maintenance
service after each 25,000 miles (41 500 km) or
24 months, whichever occurs rst. Any repairs would
not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-23
ProCarManuals.com

Notice:If your engine catches re because you
keep driving with no coolant, your vehicle can
be badly damaged. The costly repairs would not be
covered by your warranty. SeeOverheated Engine
Protection Operating Mode on page 5-28for
information on driving to a safe place in an
emergency.
If No Steam Is Coming From Your
Engine
If you get an engine overheat warning but see or hear
no steam, the problem may not be too serious.
Sometimes the engine can get a little too hot when you:
Climb a long hill on a hot day.
Stop after high-speed driving.
Idle for long periods in traffic.
Tow a trailer.If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. If your air conditioner is on, turn it off.
2. Turn on your heater to full hot at the highest fan
speed and open the windows as necessary.
3. If you are in a traffic jam, shift to NEUTRAL (N);
otherwise, shift to the highest gear while
driving — AUTOMATIC OVERDRIVE (D) or
THIRD (3).
If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning does not come back on, you can drive
normally.
If the warning continues, pull over, stop, and park your
vehicle right away.
If there is still no sign of steam, idle the engine for
three minutes while you are parked. If you still have the
warning, turn off the engine and get everyone out of
the vehicle until it cools down. Also, see “Overheated
Engine Protection Operating Mode” later in this section.
You may decide not to lift the hood but to get service
help right away.
5-27
ProCarManuals.com

The coolant level should be at or above the full cold
mark. If it is not, you may have a leak at the pressure
cap or in the radiator hoses, heater hoses, radiator,
water pump, or somewhere else in the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them. If
you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive the
vehicle.
If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fans are running.
If the engine is overheating, both fans should be
running. If they are not, your vehicle needs service.Notice:Engine damage from running your engine
without coolant is not covered by your warranty. See
Overheated Engine Protection Operating Mode on
page 5-28for information on driving to a safe place
in an emergency.
Notice:Using coolant other than DEX-COOL
®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
How to Add Coolant to the Coolant
Recovery Tank
If you have not found a problem yet, but the coolant
level is not at or above the full cold mark, add a
50/50 mixture of clean, drinkable water and DEX-COOL
®
engine coolant at the coolant recovery tank. See
Engine Coolant on page 5-23for more information.
5-30
ProCarManuals.com

{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to Saturn torque specications.
Brake linings should always be replaced as complete
axle sets.
Brake Pedal Travel
See your retailer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you apply the brakes, with or without the
vehicle moving, your brakes adjust for wear.
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality Saturn
brake parts. When you replace parts of your braking
system — for example, when your brake linings
wear down and you need new ones put in — be sure
you get new approved Saturn replacement parts. If you
do not, your brakes may no longer work properly.
For example, if someone puts in brake linings that are
wrong for your vehicle, the balance between your
front and rear brakes can change — for the worse. The
braking performance you have come to expect can
change in many other ways if someone puts in
the wrong replacement brake parts.
5-39
ProCarManuals.com