brake SATURN RELAY 2007 Repair Manual

Tire Chains
{CAUTION:
Do not use tire chains. There is not enough
clearance. Tire chains used on a vehicle
without the proper amount of clearance can
cause damage to the brakes, suspension or
other vehicle parts. The area damaged by
the tire chains could cause you to lose
control of your vehicle and you or others
may be injured in a crash.
Use another type of traction device only
if its manufacturer recommends it for
use on your vehicle and tire size
combination and road conditions.
Follow that manufacturer’s instructions.
To help avoid damage to your vehicle,
drive slowly, readjust or remove the device
if it is contacting your vehicle, and do
not spin your vehicle’s wheels. If you
do nd traction devices that will t,
install them on the front tires.
Accessory Inator
Your vehicle may have an accessory inator. With
it, you can inate things like air mattresses and
basketballs, and you can also use it to bring your
tires up to the proper pressure.
The accessory inator is located in the rear
compartment on the driver’s side. To access the
accessory inator, do the following:
1. Open the liftgate. SeeLiftgate on page 128
for more information.
2. Lift the lever to move the third row rear
seatback forward. SeeThird Row Seat
on page 27for more information.
3. Remove the cover by pulling the lever up.
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If a Tire Goes Flat
It is unusual for a tire to blowout while you are
driving, especially if you maintain your vehicle’s
tires properly. If air goes out of a tire, it is
much more likely to leak out slowly. But if you
should ever have a blowout, here are a few tips
about what to expect and what to do:
If a front tire fails, the at tire will create a drag
that pulls the vehicle toward that side. Take
your foot off the accelerator pedal and grip the
steering wheel rmly. Steer to maintain lane
position, and then gently brake to a stop well
out of the traffic lane.
A rear blowout, particularly on a curve, acts much
like a skid and may require the same correction
you would use in a skid. In any rear blowout
remove your foot from the accelerator pedal.
Get the vehicle under control by steering the
way you want the vehicle to go. It may be very
bumpy and noisy, but you can still steer. Gently
brake to a stop, well off the road if possible.{CAUTION:
Lifting a vehicle and getting under it to
do maintenance or repairs is dangerous
without the appropriate safety equipment
and training. The jack provided with your
vehicle is designed only for changing a
at tire. If it is used for anything else, you
or others could be badly injured or killed
if the vehicle slips off the jack. Use the
jack provided with your vehicle only for
changing a at tire.
If a tire goes at, the next part shows how to
use the jacking equipment to change a at
tire safely.
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Changing a Flat Tire
If a tire goes at, avoid further tire and wheel
damage by driving slowly to a level place.
Turn on your vehicle’s hazard warning ashers.
SeeHazard Warning Flashers on page 182
for more information.{CAUTION:
Changing a tire can be dangerous. The
vehicle can slip off the jack and roll over
or fall on you or other people. You and
they could be badly injured or even killed.
Find a level place to change your tire.
To help prevent the vehicle from moving:
1. Set the parking brake rmly.
2. Put the shift lever in PARK (P).
3. Turn off the engine and do not restart
while the vehicle is raised.
4. Do not allow passengers to remain
in the vehicle.
To be even more certain the vehicle will
not move, you should put blocks at the
front and rear of the tire farthest away
from the one being changed. That would
be the tire, on the other side, at the
opposite end of the vehicle.
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{CAUTION:
Incorrect wheel nuts or improperly
tightened wheel nuts can cause the wheel
to come loose and even come off. This
could lead to an accident. Be sure to use
the correct wheel nuts. If you have to
replace them, be sure to get new GM
original equipment wheel nuts. Stop
somewhere as soon as you can and have
the nuts tightened with a torque wrench
to the proper torque specication. See
Capacities and Specifications on page 518
for wheel nut torque specication.
Notice:Improperly tightened wheel nuts can
lead to brake pulsation and rotor damage.
To avoid expensive brake repairs, evenly
tighten the wheel nuts in the proper sequence
and to the proper torque specication.
SeeCapacities and Specifications on page 518
for the wheel nut torque specication.10. Tighten the wheel
nuts rmly in a
crisscross sequence,
as shown.
Notice:Wheel covers will not t on your
compact spare. If you try to put a wheel cover
on the compact spare, you could damage
the cover or the spare.
11. Do not try to put a wheel cover on the
compact spare tire. It will not t. Store
the wheel cover securely in the rear of the
vehicle until you have the at tire repaired
or replaced.
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Fuses Usage
BLANK Not Used
4 Left High-Beam
BLANK Not Used
BLANK Not Used
BLANK Not Used
5 Not Used
6 Air Conditioning Clutch
7 Horn
8 Left Low-Beam
9Powertrain Control Module,
Electronic Throttle Control
10 Not Used
11 Transmission Solenoid
12 Right Low-Beam
13 Anti-lock Brake System
14 Powertrain Control Module IgnitionFuses Usage
15 Electronic Ignition
16 Fuel Injector
17Climate Control, RPA,
Cruise Control
18 Electronic Throttle Control
19 Engine Sensor, Evaporator
20 Airbag
21 Not Used
22 Not Used
23 Auxiliary Power
24 Front Windshield Washer
25 AC/DC Inverter
26 Rear Blower
27 Front Blower
28 Front Windshield Wiper
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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 SpareRelays 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 423. Reset oil life system.
SeeEngine Oil Life System on page 426.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 428.See footnote (g).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 472and “Tire Wear Inspection” inAt Least Once a Month on
page 527.••
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.•
Replace passenger compartment air lter.See footnote (l).•
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.
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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 147.
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.
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 147.
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.
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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 ignition key should come out only in LOCK.
Contact your Saturn retailer if service is required.
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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