brake SATURN SKY 2007 Workshop Manual

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.
Battery
Your vehicle has a maintenance free battery.
When it is time for a new battery, get one that has
the replacement number shown on the original
battery’s label. We recommend an ACDelco
®
replacement battery. SeeEngine Compartment
Overview on page 242for battery location.
Warning:Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California
to cause cancer and reproductive harm.
Wash hands after handling.
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Notice:Ignoring these steps could result in
costly damage to your vehicle that would
not be covered by your warranty.
Trying to start your vehicle by pushing or
pulling it will not work, and it could damage
your vehicle.
1. Check the other vehicle. It must have a
12-volt battery with a negative ground system.
Notice:If the other vehicle’s system is not
a 12-volt system with a negative ground, both
vehicles can be damaged. Only use vehicles
with 12-volt systems with negative grounds to
jump start your vehicle.
2. Get the vehicles close enough so the jumper
cables can reach, but be sure the vehicles are
not touching each other. If they are, it could
cause a ground connection you do not
want. You would not be able to start your
vehicle, and the bad grounding could damage
the electrical systems.To avoid the possibility of the vehicles rolling,
set the parking brake rmly on both vehicles
involved in the jump start procedure. Put
an automatic transmission in PARK (P) or a
manual transmission in NEUTRAL before
setting the parking brake.
Notice:If you leave your radio or other
accessories on during the jump starting
procedure, they could be damaged. The
repairs would not be covered by your
warranty. Always turn off your radio and
other accessories when jump starting
your vehicle.
3. Turn off the ignition on both vehicles.
Unplug unnecessary accessories plugged
into the cigarette lighter or the accessory
power outlet. Turn off the radio and all lamps
that are not needed. This will avoid sparks
and help save both batteries. And it could
save the radio!
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Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire
pressing outward on each square inch of the
tire. Air pressure is expressed in pounds
per square inch (psi) or kilopascal (kPa).
Accessory Weight:This means the combined
weight of optional accessories. Some examples of
optional accessories are, automatic transmission/
transaxle, power steering, power brakes, power
windows, power seats, and air conditioning.
Aspect Ratio:The relationship of a tire’s height
to its width.
Belt:A rubber coated layer of cords that is
located between the plies and the tread. Cords
may be made from steel or other reinforcing
materials.
Bead:The tire bead contains steel wires wrapped
by steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the
plies are laid at alternate angles less than
90 degrees to the centerline of the tread.Cold Tire Pressure:The amount of air pressure
in a tire, measured in pounds per square
inch (psi) or kilopascals (kPa) before a tire has
built up heat from driving. SeeInation - Tire
Pressure on page 292.
Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment
including the maximum capacity of fuel, oil, and
coolant, but without passengers and cargo.
DOT Markings:A code molded into the sidewall
of a tire signifying that the tire is in compliance
with the U.S. Department of Transportation (DOT)
motor vehicle safety standards. The DOT code
includes the Tire Identication Number (TIN),
an alphanumeric designator which can also identify
the tire manufacturer, production plant, brand,
and date of production.
GVWR:Gross Vehicle Weight Rating. See
Loading Your Vehicle on page 225.
GAWR FRT:Gross Axle Weight Rating for the
front axle. SeeLoading Your Vehicle on page 225.
GAWR RR:Gross Axle Weight Rating for the
rear axle. SeeLoading Your Vehicle on page 225.
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When It Is Time for New Tires
One way to tell when it
is time for new tires is
to check the treadwear
indicators, which will
appear when your tires
have only 1/16 inch
(1.6 mm) or less of
tread remaining.
You need a new tire if any of the following
statements are true:
You can see the indicators at three or more
places around the tire.
You can see cord or fabric showing through
the tire’s rubber.
The tread or sidewall is cracked, cut, or
snagged deep enough to show cord or fabric.
The tire has a bump, bulge, or split.
The tire has a puncture, cut, or other damage
that cannot be repaired well because of the
size or location of the damage.
Buying New Tires
Saturn has developed and matched specic tires
for your vehicle. The original equipment tires
installed on your vehicle, when it was new,
were designed to meet General Motors Tire
Performance Criteria Specication (TPC spec)
system rating. If you need replacement tires,
Saturn strongly recommends that you get tires
with the same TPC spec rating. This way, your
vehicle will continue to have tires that are designed
to give the same performance and vehicle safety,
during normal use, as the original tires.
GM’s exclusive TPC spec system considers over
a dozen critical specications that impact the
overall performance of your vehicle, including
brake system performance, ride and handling,
traction control, and tire pressure monitoring
performance. GM’s TPC spec number is molded
onto the tire’s sidewall by the tire manufacturer.
If the tires have an all-season tread design,
the TPC spec number will be followed by a MS,
for mud and snow. SeeTire Sidewall Labeling
on page 287for additional information.
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Different Size Tires and Wheels
If you add wheels or tires that are a different
size than your original equipment wheels and
tires, this may affect the way your vehicle
performs, including its braking, ride and handling
characteristics, stability, and resistance to
rollover. Additionally, if your vehicle has electronic
systems such as, anti-lock brakes, traction
control, and stability control, the performance
of these systems can be affected.{CAUTION:
If you add different sized wheels, your
vehicle may not provide an acceptable
level of performance and safety if tires
not recommended for those wheels are
selected. You may increase the chance
that you will crash and suffer serious
injury. Only use Saturn specic wheel and
tire systems developed for your vehicle,
and have them properly installed by a
Saturn certied technician.
SeeBuying New Tires on page 296and
Accessories and Modications on page 233for
additional information.
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Each new wheel should have the same
load-carrying capacity, diameter, width, offset and
be mounted the same way as the one it replaces.
{CAUTION:
Using the wrong replacement wheels,
wheel bolts, or wheel nuts on your vehicle
can be dangerous. It could affect the
braking and handling of your vehicle,
make your tires lose air and make you
lose control. You could have a collision
in which you or others could be injured.
Always use the correct wheel, wheel bolts,
and wheel nuts for replacement.
If you need to replace any of your wheels, wheel
bolts, or wheel nuts, replace them only with
new Saturn original equipment parts. This way,
you will be sure to have the right wheel, wheel
bolts, and wheel nuts for your vehicle.Notice:The wrong wheel can also cause
problems with bearing life, brake cooling,
speedometer or odometer calibration,
headlamp aim, bumper height, vehicle ground
clearance, and tire clearance to the body
and chassis.{CAUTION:
Rust or dirt on a wheel, or on the parts to
which it is fastened, can make wheel nuts
become loose after a time. The wheel
could come off and cause a crash. When
you change a wheel, remove any rust or
dirt from places where the wheel attaches
to the vehicle. In an emergency, you can
use a cloth or a paper towel to do this;
but be sure to use a scraper or wire brush
later, if you need to, to get all the rust or
dirt off.
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{CAUTION:
Never use oil or grease on studs or the
threads of the wheel nuts. If you do, the
wheel nuts might come loose and the
wheel could fall off, causing a crash.
{CAUTION:
Incorrect wheel nuts or improperly
tightened wheel nuts can cause the wheel
to become loose and even come off.
This could lead to a crash. Be sure to
use the correct wheel nuts. If you have to
replace them, be sure to get new Saturn
original equipment wheel nuts.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.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You cannot know how it has
been used or how far it has been driven.
It could fail suddenly and cause a crash.
If you have to replace a wheel, use a new
Saturn original equipment wheel.
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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, re-adjust or
remove the device if it is contacting your
vehicle, and do not spin your wheels.
If you do nd traction devices that will t,
install them on the rear tires.
If a Tire Goes Flat
Your vehicle has a tire inator kit. There is no
spare tire, no tire changing equipment, and
no place to store a tire.
It is unusual for a tire to blow out while you are
driving, especially if you maintain your tires
properly. SeeTires on page 284. If air goes out
of a tire, it is much more likely to leak out slowly.
But, if you should ever have a blow out, 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 blow out, particularly on a curve, acts much
like a skid and may require the same correction
you would use in a skid. In any rear blow out,
remove your foot from the accelerator pedal.
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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.
If a tire goes at, avoid further tire and wheel
damage by driving slowly to a level place
and stopping. Then do this:
1. Turn on the hazard warning ashers. See
Hazard Warning Flashers on page 110.
2. Park your vehicle. If your vehicle has an
automatic transmission, set the parking
brake rmly and put the shift lever in
PARK (P). SeeShifting Into Park (P)
(Automatic Transmission) on page 87.
If your vehicle has a manual transmission,
move the shift lever to REVERSE (R) and
set the parking brake rmly. SeeParking
Your Vehicle (Manual Transmission) on
page 89for additional information.
3. Turn off the engine.
4. Inspect the at tire.If the tire has been separated from the wheel
or has damaged sidewalls or large tears that
allow rapid air loss, call a tire repair facility. See
Roadside Assistance Program on page 359.
If the at tire is due to a slow leak caused by a
nail or other similar road hazard, the tire inator
kit may be used to repair the damaged tire
temporarily. The kit uses a liquid tire sealant to
seal small punctures in the tread area of the tire.
After repairing a tire with the tire inator kit,
take your vehicle to an authorized Saturn retailer
to have the tire inspected and repaired as
soon as possible. The tire sealant is a temporary
repair only. SeeTire Inator Kit on page 304.
Tire Inator Kit
Your vehicle has a tire inator kit. There is no jack
or spare tire. The kit uses a liquid tire sealant
and air at the same time to seal small punctures
in the tread area of the tire. Be sure to read
and follow all of the tire inator kit instructions.
The kit includes the following:
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Fuses Usage
43Engine Control Module,
Transmission
44 Anti-lock Brake System
45Injectors, Ignition Coils (LE5);
Ignition Coils (LNF)
46Back-up Lamps
(Manual Transmission);
Empty (Automatic Transmission)
47 Empty
48 Daytime Running Lamps Relay
49 Daytime Running Lamps
50Cooling Fan 1 Relay (LE5);
Empty (LNF)
51 Run/Crank Relay
52 Windshield Wiper Low/High Relay
53 Fog Lamps
54 Fog Lamps Relay
55 Horn Relay
56S Band, OnStar
®, Remote
Keyless Entry System
Fuses Usage
57 Anti-lock Brake System
58 Wiper Diode
59 Windshield Wiper
60 Horn
61 Anti-lock Brake System
62 Instrument Panel Ignition
63 Driver’s Side High Beam
64 Canister Vent
65 Driver’s Side Low-Beam Headlamp
66Passenger’s Side Low-Beam
Headlamp
67Passenger’s Side High-Beam
Headlamp
68 Parking Lamps Relay
69 Parking Lamps
70 Windshield Wiper On/Off Relay
71 Low-Beam Headlamp Relay
72 High-Beam Headlamp Relay
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