engine SATURN ASTRA 2009 Workshop Manual

Automatic Transmission
Fluid
It is not necessary to check
the transmission uid level.
A transmission uid leak is the
only reason for uid loss. If a leak
occurs, take your vehicle to the
dealer/retailer service department
and have it repaired as soon
as possible.
Change the uid and lter at the
intervals listed in the Maintenance
Schedule. See “Additional
Required Services” in Service and
Maintenance. Be sure to use
the transmission uid listed in
“Recommended Fluids and
Lubricants” in Service and
Maintenance.
Notice:Use of the incorrect
automatic transmission uid
may damage your vehicle, and
the damages may not be
covered by your warranty.See “Recommended Fluids and
Lubricants” in the Limited
Warranty, Maintenance and Owner
Assistance Information manual.
Manual Transmission
Fluid
It is not necessary to check the
manual transmission uid level.
A transmission uid leak is the
only reason for uid loss. If a leak
occurs, take the vehicle to the
dealer/retailer service department
and have it repaired as soon
as possible. You may also have
your uid level checked by your
dealer/retailer when you have
your oil changed. See “Part D:
Recommended Fluids and
Lubricants” in Service and
Maintenance for the proper uid
to use.
Hydraulic Clutch
The hydraulic clutch linkage in
your vehicle is self-adjusting.
This system does not have its own
reservoir. It receives uid from
the brake master cylinder reservoir.
SeeBrakes on page 9-22for
more information.
Cooling System
When you decide it is safe to lift the
hood, this is what you see:
A.
Coolant Reservoir
B.Coolant Reservoir Pressure Cap
C.Engine Cooling Fans (Out of view)
9-12 Vehicle Service and Care
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{CAUTION
An electric engine cooling fan
under the hood can start up even
when the engine is not running and
can cause injury. Keep hands,
clothing, and tools away from any
underhood electric fan.
If the coolant inside the coolant
reservoir is boiling, do not do
anything else until it cools down.
The vehicle should be parked on a
level surface.
The coolant level should be at or
above the KALT/COLD mark on the
coolant reservoir. If it is not, you
may have a leak at the coolant
reservoir 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 the engine without
coolant is not covered by the
warranty.
Notice:Using coolant other
than DEX-COOL
®can cause
premature engine, heater core, or
radiator corrosion. In addition,
the engine coolant could require
changing sooner, at 30,000 miles
(50 000 km) or 24 months,
whichever occurs rst.
Any repairs would not be
covered by the vehicle warranty.
Always use DEX-COOL
®
(silicate-free) coolant in the
vehicle.
Vehicle Service and Care 9-13
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How to Add Coolant to the
Coolant Reservoir
Notice:This vehicle has a
specic coolant ll procedure.
Failure to follow this procedure
could cause the engine to
overheat and be severely
damaged.
If you have not found a problem yet,
check to see if coolant is visible
in the coolant reservoir. If coolant is
visible but the coolant level is not
at or above the KALT/COLD mark,
add a 50/50 mixture of clean,
drinkable water and DEX-COOL
®
coolant at the coolant reservoir,
but be sure the cooling system,
including the coolant reservoir
pressure cap, is cool before you
do it. SeeEngine Coolant on
page 9-16for more information.If no coolant is visible in the coolant
reservoir, add coolant as follows:
{CAUTION
Steam and scalding liquids from a
hot cooling system can blow out
and burn you badly. They are
under pressure, and if you turn
the coolant reservoir pressure
cap — even a little — they can
come out at high speed. Never
turn the cap when the cooling
system, including the coolant
reservoir pressure cap, is hot.
Wait for the cooling system and
coolant reservoir pressure cap to
cool if you ever have to turn the
pressure cap.
{CAUTION
Adding only plain water to the
cooling system can be dangerous.
Plain water, or some other liquid
such as alcohol, can boil before
the proper coolant mixture will.
The vehicle’s coolant warning
system is set for the proper
coolant mixture. With plain water
or the wrong mixture, the engine
could get too hot but you would
not get the overheat warning.
The engine could catch re and
you or others could be burned.
Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®
coolant.
Notice:In cold weather, water
can freeze and crack the engine,
radiator, heater core and other
parts. Use the recommended
coolant and the proper coolant
mixture.
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{CAUTION
You can be burned if you spill
coolant on hot engine parts.
Coolant contains ethylene glycol
and it will burn if the engine parts
are hot enough. Do not spill
coolant on a hot engine.
1. Remove the coolant reservoir
pressure cap when the cooling
system, including the coolant
reservoir pressure cap and upper
radiator hose, is no longer hot.
Turn the coolant reservoir
pressure cap slowly
counterclockwise about two or
two and one-half turns.
If you hear a hiss, wait for that
to stop. This will allow any
pressure still left to be vented
out the discharge hose.2. Keep turning the coolant
reservoir pressure cap slowly,
and remove it.
3. Fill the coolant reservoir with
the proper mixture, to the
KALT/COLD mark. Wait about
ve minutes, then check to see
if the level is below the mark.
If the level is below the
KALT/COLD mark, add additional
coolant to bring the level up to
the mark. Repeat this procedure
until the level remains constant
at the KALT/COLD mark for
at least ve minutes.4. With the coolant reservoir
pressure cap off, start the
engine and let it run until you
can feel the upper radiator hose
getting hot. Watch out for the
engine cooling fans.
By this time, the coolant level
inside the coolant reservoir might
be lower. If the level is lower
than the KALT/COLD mark,
add more of the proper
mixture to the coolant reservoir
until the level reaches the
KALT/COLD mark.
5. Replace the coolant reservoir
pressure cap. Be sure the
pressure cap is hand-tight and
fully seated. Coolant Reservoir Pressure Cap
Vehicle Service and Care 9-15
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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, see
Engine Overheating on page 9-18.
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 lights and gages
work as they should.
Notice:Using coolant other than
DEX-COOL
®can 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
the vehicle warranty. Always
use DEX-COOL
®(silicate-free)
coolant in the vehicle.
What to Use
Use a mixture of one-half clean,
drinkable water and one-half
DEX-COOL
®coolant which will not
damage aluminum parts. If you
use this coolant mixture, you do not
need to add anything else.
{CAUTION
Adding only plain water to the
cooling system can be dangerous.
Plain water, or some other liquid
such as alcohol, can boil before
the proper coolant mixture will.
The vehicle’s coolant warning
system is set for the proper
coolant mixture. With plain water
or the wrong mixture, the engine
could get too hot but would not
get the overheat warning. The
engine could catch re and you or
others could be burned. Use a
50/50 mixture of clean, drinkable
water and DEX-COOL
®coolant.
9-16 Vehicle Service and Care
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Notice:If an improper coolant
mixture is used, the engine could
overheat and be badly damaged.
The repair cost would not be
covered by the vehicle warranty.
Too much water in the mixture
can freeze and crack the engine,
radiator, heater core, and
other parts.
Notice:If you use extra
inhibitors and/or additives in
your vehicle’s cooling system,
you could damage your vehicle.
Use only the proper mixture of
the engine coolant listed in
this manual for the cooling
system. See Recommended
Fluids and Lubricants in the
Maintenance and Limited
Warranty and Owner Assistance
Information manual.Checking Coolant
The coolant reservoir is located in
the engine compartment on the
driver’s side of the vehicle.
SeeEngine Compartment Overview
on page 9-6for more information
on location.
{CAUTION
Turning the coolant reservoir
pressure cap when the engine
and radiator are hot can allow
steam and scalding liquids to blow
out and burn you badly. Never
turn the coolant reservoir pressure
cap – even a little – when the
engine and radiator are hot.
The vehicle must be on a level
surface. When your engine is cold,
the coolant level should be at
the KALT/COLD line.
Do not overll the coolant reservoir.
Too much coolant can result in
an overow condition when the
uid is hot.
Vehicle Service and Care 9-17
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Adding Coolant
If you need more coolant, add the
proper DEX-COOL®coolant mixture
at the coolant reservoir, but only
when the engine is cool. If the
coolant reservoir is empty, a
special ll procedure is necessary.
SeeCooling System on page 9-12
for instructions on “How to Add
Coolant to the Coolant Reservoir.”
{CAUTION
You can be burned if you spill
coolant on hot engine parts.
Coolant contains ethylene glycol,
and it will burn if the engine parts
are hot enough. Do not spill
coolant on a hot engine.
When replacing the pressure cap,
make sure it is hand-tight and
fully seated.
Pressure Cap
Notice:If the pressure cap is not
tightly installed, coolant loss
and possible engine damage may
occur. Be sure the cap is
properly and tightly secured.
SeeEngine Compartment Overview
on page 9-6for more information
on location.
Engine Overheating
There is an engine coolant
temperature warning light on your
vehicle’s instrument panel. See
Engine Coolant Temperature
Warning Light on page 4-18for
more information.
If Steam Is Coming From
Your Engine
{CAUTION
Steam from an overheated engine
can burn you badly, even if you
just open the hood. Stay away
from the engine if you see or hear
steam coming from it. Just turn it
off and get everyone away from
the vehicle until it cools down.
Wait until there is no sign of
steam or coolant before you open
the hood.
If you keep driving when your
engine is overheated, the liquids in
it can catch re. You or others
could be badly burned. Stop your
engine if it overheats, and get out
of the vehicle until the engine
is cool.
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Notice:If the engine catches re
because of being driven with
no coolant, your vehicle can be
badly damaged. The costly
repairs would not be covered by
the vehicle warranty.
If No Steam Is Coming From
Your Engine
An engine coolant temperature
warning can indicate a serious
problem. SeeEngine Coolant
Temperature Warning Light on
page 4-18.
If you get an engine coolant
temperature 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.If you get the engine coolant
temperature warning with no sign of
steam, try this for a minute or so:
1. If your air conditioner is on,
turn it off.
2. In heavy traffic, let the engine
idle in N (Neutral) while
stopped. If it is safe to do so,
pull off the road, shift to P (Park)
or N (Neutral) and let the
engine idle.
3. Turn on your heater to full hot at
the highest fan speed and open
the windows as necessary.
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 and you
have not stopped, pull over,
stop, and park your vehicle
right away.
If there is still no sign of steam,
you can 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.
You may decide not to lift the hood
but to get service help right away.
Vehicle Service and Care 9-19
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Power Steering Fluid
When to Check Power
Steering Fluid
It is not necessary to check the
power steering uid level. A power
steering uid leak is the only
reason for uid loss. If a leak
occurs, take your vehicle to the
dealer/retailer service department
and have it repaired as soon
as possible.
Windshield Washer Fluid
What to Use
When you need windshield
washer uid, be sure to read the
manufacturer’s instructions before
use. If you will be operating
your vehicle in an area where
the temperature may fall below
freezing, use a uid that has
sufficient protection against freezing.
Adding Washer Fluid
Open the cap with the washer
symbol on it. Add washer uid
until the tank is full. SeeEngine
Compartment Overview on page 9-6
for reservoir location.Notice:
When using concentrated
washer uid, follow the
manufacturer’s instructions
for adding water.
Do not mix water with
ready-to-use washer uid.
Water can cause the solution
to freeze and damage your
washer uid tank and other
parts of the washer system.
Also, water does not clean as
well as washer uid.
Fill the washer uid tank only
three-quarters full when it is
very cold. This allows for uid
expansion if freezing occurs,
which could damage the tank
if it is completely full.
Do not use engine coolant
(antifreeze) in your windshield
washer. It can damage the
vehicle’s windshield washer
system and paint.
9-20 Vehicle Service and Care
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Brakes
Brake Fluid
The brake master cylinder and, on
manual transmission vehicles,
the clutch hydraulic system use the
same reservoir. The reservoir is
lled with DOT-4 brake uid.
SeeEngine Compartment Overview
on page 9-6for the location of
the reservoir.
There are only two reasons why the
brake uid level in the reservoir
might go down:
The brake uid level goes down
because of normal brake lining
wear. When new linings are
installed, the uid level goes
back up.
A uid leak in the brake and/or
clutch hydraulic system can also
cause a low uid level. Have the
brake and/or clutch hydraulic
system xed, since a leak means
that sooner or later the brakes
and/or clutch will not work well.
Do not top off the brake/clutch uid.
Adding uid does not correct a leak.
If uid is added when the brake
linings are worn, there will be too
much uid when new brake linings
are installed. Add or remove uid, as
necessary, only when work is done
on the brake/clutch hydraulic system.
{CAUTION
If too much brake uid is added,
it can spill on the engine and
burn, if the engine is hot enough.
You or others could be burned,
(Continued)
CAUTION (Continued)
and the vehicle could be
damaged. Add brake uid only
when work is done on the brake
and/or clutch hydraulic system.
Refer toScheduled Maintenance on
page 11-3to determine when to
check the brake uid.
Checking Brake Fluid
The brake uid can be checked
without taking off the cap by looking
at the brake uid reservoir.
The uid level should be above
MIN. If it is not, have your brake
hydraulic system checked to see if
there is a leak. After work is
done on the brake hydraulic system,
make sure the level is above the
MIN but not over the MAX mark.
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