service SATURN RELAY 2007 Repair Manual

Your vehicle has an airbag system. Before
attempting to do your own service work, see
Servicing Your Airbag-Equipped Vehicle on
page 99.
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 534.
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.
To help keep your engine clean and maintain
optimum vehicle performance, Saturn recommends
the use of gasoline advertised as TOP TIER
Detergent Gasoline.
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.
Gasoline Specications
At a minimum, gasoline should meet ASTM
specication D 4814 in the United States or
CAN/CGSB-3.5 in Canada. Some gasolines may
contain an octane-enhancing additive called
methylcyclopentadienyl manganese tricarbonyl
(MMT). Saturn recommends against the use
of gasolines containing MMT. SeeAdditives on
page 415for additional information.
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Gasolines containing oxygenates, such as ethers
and ethanol, and reformulated gasolines may
be available in your area. General Motors
recommends that you use these gasolines if they
comply with the specications described earlier.
However, E85 (85% ethanol) and other fuels
containing more than 10% ethanol must not be
used in vehicles that were not designed for
those fuels.
Notice:Your vehicle was not designed for
fuel that contains methanol. Do not use
fuel containing methanol. It can corrode metal
parts in your fuel system and also damage
the plastic and rubber parts. That damage
would not be covered under your warranty.
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.
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If the system is ever reset accidentally, you
must change your oil at 3,000 miles (5 000 km)
since your last oil change. Remember to reset
the oil life system whenever the oil is changed.
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.
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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 524, and
be sure to use the transaxle uid listed in
Recommended Fluids and Lubricants on page 530.
How to Check Automatic Transaxle
Fluid
Because this operation can be a little difficult,
you may choose to have this done at the
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.
Wait at least 30 minutes before checking the
transaxle uid level if you have been driving:
When outside temperatures are above
90°F (32°C).
At high speed for quite a while.
In heavy traffic — especially in hot weather.
While pulling a trailer.
To get the right reading, the uid should be
at normal operating temperature, which is
180°F to 200°F (82°C to 93°C).
Get the vehicle warmed up by driving about
15 miles (24 km) when outside temperatures are
above 50°F (10°C). If it is colder than 50°F (10°C),
you may have to drive longer.
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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 435.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
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.
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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 — DRIVE (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.Overheated Engine Protection
Operating Mode
This emergency operating mode allows your
vehicle to be driven to a safe place in an
emergency situation. If an overheated engine
condition exists, an overheat protection mode
which alternates ring groups of cylinders helps
prevent engine damage. In this mode, you
will notice a signicant loss in power and engine
performance. The temperature gage will
indicate an overheat condition exists. Driving
extended miles (km) and/or towing a trailer in the
overheat protection mode should be avoided.
Notice:After driving in the overheated engine
protection operating mode, to avoid engine
damage, allow the engine to cool before
attempting any repair. The engine oil will be
severely degraded. Repair the cause of coolant
loss, change the oil and reset the oil life
system. SeeEngine Oil on page 423.
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{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. SeeOverheated Engine Protection
Operating Mode on page 437for 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.
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Notice:
Using the wrong uid can badly damage
brake system parts. For example, just a
few drops of mineral-based oil, such
as engine oil, in your brake system can
damage brake system parts so badly that
they will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s
painted surfaces, the paint nish can
be damaged. Be careful not to spill brake
uid on your vehicle. If you do, wash it
off immediately. SeeWashing Your Vehicle
on page 505.
Brake Wear
Your vehicle has four-wheel disc brakes.
Disc brake pads have built-in wear indicators that
make a high-pitched warning sound when the
brake pads are worn and new pads are needed.
The sound may come and go or be heard all
the time your vehicle is moving, except when
you are pushing on the brake pedal rmly.
{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.
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9. Connect the other end of the negative (−)
cable at least 18 inches (45 cm) away from
the dead battery, but not near engine
parts that move. The electrical connection
is just as good there, and the chance of
sparks getting back to the battery is
much less.
10. Now start the vehicle with the good battery
and run the engine for a while.
11. Try to start the vehicle that had the dead
battery. If it will not start after a few tries,
it probably needs service.
Notice:If the jumper cables are connected
or removed in the wrong order, electrical
shorting may occur and damage the vehicle.
The repairs would not be covered by your
warranty. Always connect and remove
the jumper cables in the correct order,
making sure that the cables do not touch
each other or other metal.A. Heavy, Unpainted Metal Engine Part or
Remote Negative (−) Terminal
B. Good Battery or Remote Positive (+) Terminal
and Remote Negative (−) Terminals
C. Dead Battery or Remote Positive (+) Terminal
Jumper Cable Removal
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Tires
Your new vehicle comes with high-quality tires
made by a leading tire manufacturer. If you ever
have questions about your tire warranty and where
to obtain service, see your Saturn Warranty
booklet for details. For additional information refer
to the tire manufacturer’s booklet included with
your vehicle.
{CAUTION:
Poorly maintained and improperly used
tires are dangerous.
Overloading your vehicle’s tires can
cause overheating as a result of too
much friction. You could have an
air-out and a serious accident. See
Loading Your Vehicle on page 391.
CAUTION: (Continued)
CAUTION: (Continued)

Underinated tires pose the same
danger as overloaded tires. The
resulting accident could cause serious
injury. Check all tires frequently to
maintain the recommended pressure.
Tire pressure should be checked when
your vehicle’s tires are cold. See
Inflation - Tire Pressure on page 469.
Overinated tires are more likely to
be cut, punctured, or broken by a
sudden impact — such as when you
hit a pothole. Keep tires at the
recommended pressure.
Worn, old tires can cause accidents.
If the tire’s tread is badly worn, or
if your vehicle’s tires have been
damaged, replace them.
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