SATURN ION 2004 Owners Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-15
Engine Air Cleaner/Filter................................5-22
Automatic Transaxle Fluid..............................5-24
Manual Transaxle Fluid..................................5-25
Hydraulic Clutch...........................................5-25
Engine Coolant.............................................5-26Coolant Surge Tank Pressure Cap..................5-29
Engine Overheating.......................................5-29
Cooling System............................................5-32
Windshield Washer Fluid................................5-37
Brakes........................................................5-38
Battery........................................................5-41
Jump Starting...............................................5-42
Headlamp Aiming...........................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps (Sedan)......................................5-48
Headlamps (Coupe)......................................5-50
Front Turn Signal Lamps (Sedan)...................5-51
Front Turn Signal and Parking Lamps
(Coupe)...................................................5-53
Fog Lamps..................................................5-53
Sidemarker Lamps (Coupe)............................5-54
Center High-Mounted Stoplamp (CHMSL).........5-55
Taillamps, Stoplamps and Back-up Lamps........5-55
Replacement Bulbs.......................................5-56
Section 5 Service and Appearance Care
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Windshield Wiper Blade Replacement..............5-57
Tires..............................................................5-58
Ination - Tire Pressure.................................5-66
Tire Inspection and Rotation...........................5-68
When It Is Time for New Tires.......................5-69
Buying New Tires.........................................5-70
Uniform Tire Quality Grading..........................5-71
Wheel Alignment and Tire Balance..................5-72
Wheel Replacement......................................5-72
Tire Chains..................................................5-74
If a Tire Goes Flat........................................5-75
Changing a Flat Tire.....................................5-76
Compact Spare Tire......................................5-86
Appearance Care............................................5-87
Cleaning the Inside of Your Vehicle.................5-87
Care of Safety Belts......................................5-89
Weatherstrips...............................................5-90Cleaning the Outside of Your Vehicle..............5-90
Sheet Metal Damage.....................................5-92
Finish Damage.............................................5-92
Underbody Maintenance................................5-92
Chemical Paint Spotting.................................5-92
Vehicle Care/Appearance Materials..................5-93
Vehicle Identication......................................5-94
Vehicle Identication Number (VIN).................5-94
Service Parts Identication Label.....................5-94
Electrical System............................................5-95
Add-On Electrical Equipment..........................5-95
Windshield Wiper Fuses................................5-95
Power Windows and Other Power Options.......5-95
Fuses and Circuit Breakers............................5-95
Capacities and Specications........................5-102
Section 5 Service and Appearance Care
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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.
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.
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Doing Your Own Service Work
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 7-10.
Your vehicle has an air bag system. Before attempting
to do your own service work, seeServicing Your Air
Bag-Equipped Vehicle on page 1-58.
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 6-18.
{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.
CAUTION: (Continued)
CAUTION: (Continued)

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.
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.
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Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
If your vehicle has the 2.2L L4 engine, use regular
unleaded gasoline with a posted octane of 87 or higher.
If the octane is less than 87, you may get a heavy
knocking noise when you drive. If this occurs, use a
gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine.
A little pinging noise when you accelerate or drive uphill
is considered normal. This does not indicate a problem
exists or that a higher-octane fuel is necessary.
If you are using 87 octane or higher-octane fuel and
hear heavy knocking, your engine needs service.
If your vehicle has the 2.0L Supercharged engine, use
premium unleaded gasoline with a posted octane of
91 or higher for best performance. You may also
use middle grade or regular unleaded gasoline rated
at 87 octane or higher, but your vehicle’s acceleration
may be slightly reduced. If the octane is less than
87, you may get a heavy knocking noise when you drive.
If this occurs, use a gasoline rated at 87 octane or
higher as soon as possible. Otherwise, you might
damage your engine.
Gasoline Specications
It is recommended that gasoline meet specications
which were developed by automobile manufacturers
around the world and contained in the World-Wide
Fuel Charter which is available from the
Alliance of Automobile Manufacturers at
www.autoalliance.org/fuel_charter.htm. Gasoline
meeting these specications could provide improved
driveability and emission control system performance
compared to other gasoline.
In Canada, look for the
“Auto Makers’ Choice”
label on the pump.
Canada Only
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California Fuel
If your vehicle is certied to meet California Emission
Standards (see the underhood emission control
label), it is designed to operate on fuels that meet
California specications. If this fuel is not available in
states adopting California emissions standards,
your vehicle will operate satisfactorily on fuels meeting
federal specications, but emission control system
performance may be affected. The malfunction indicator
lamp may turn on (seeMalfunction Indicator Lamp
on page 3-36) and your vehicle may fail a smog-check
test. If this occurs, return to your authorized Saturn
retailer for diagnosis. If it is determined that the condition
is caused by the type of fuel used, repairs may not be
covered by your warranty.
Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that will help
prevent engine and fuel system deposits from forming,
allowing your emission control system to work
properly. You should not have to add anything to your
fuel. However, some gasolines contain only the
minimum amount of additive required to meet U.S.
Environmental Protection Agency regulations. General
Motors recommends that you buy gasolines that
are advertised to help keep fuel injectors and intake
valves clean. If your vehicle experiences problems due
to dirty injectors or valves, try a different brand of
gasoline.
Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines may be available in
your area to contribute to clean air. General Motors
recommends that you use these gasolines, particularly if
they comply with the specications described earlier.
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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 does
not recommend 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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Filling Your 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
CAUTION: (Continued)
CAUTION: (Continued)
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.
The fuel ller cap is located behind a hinged door on
the passenger’s side of your vehicle. It is tethered to the
door to prevent loss while refueling. Make sure that
water, snow, and dirt are kept away from the ller cap
and ller pipe nozzle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). It will require about 1/2 of a turn
to remove the cap. The fuel cap has a spring in it; if you
let go of the cap too soon, it will spring back to the
right (clockwise).
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{CAUTION:
If you get fuel on yourself and then something
ignites it, you could be badly burned. Fuel can
spray out on you if you open the fuel cap too
quickly. This spray can happen if your tank is
nearly full, and is more likely in hot weather.
Open the fuel cap slowly and wait for any “hiss”
noise to stop. Then unscrew the cap all the way.
Be careful not to spill fuel. Clean fuel from painted
surfaces as soon as possible. SeeCleaning the Outside
of Your Vehicle on page 5-90.
When you put the fuel cap back on, turn it to the right
(clockwise) about 1/4 of a turn until you hear three
clicks. Make sure you fully install the cap. The diagnostic
system can determine if the fuel cap has been left off
or improperly installed. This would allow fuel to
evaporate into the atmosphere and may cause the
malfunction indicator lamp to come on. SeeMalfunction
Indicator Lamp on page 3-36.
Notice:If you need a new fuel cap, be sure to get the
right type. Your dealer can get one for you. If you get
the wrong type, it may not t properly. This may cause
your malfunction indicator lamp to light and may
damage your fuel tank and emissions system.
SeeMalfunction Indicator Lamp on page 3-36.
Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
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Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up
and injure you even when the engine is not
running. Keep hands, clothing and tools away
from any underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts
and start a re. These include liquids like fuel,
oil, coolant, brake uid, windshield washer and
other uids, and plastic or rubber. You or
others could be burned. Be careful not to drop
or spill things that will burn onto a hot engine.
Hood Release
To open the hood, do the following:
1. Pull the handle located
inside the vehicle.
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