air condition SATURN ION 2004 Owner's Manual

Fuses Usage
18 HDLP-LH Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 PREM AUDIOEntertainment, Premium Radio
Amplier
22 ABSAnti-Lock Brake System,
Traction Control Module
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABSAnti-Lock Brake System,
Traction Control Module
41 IP BATT2 Body Control Module
42 EPS2 Electric Power Steering
43 EPS1 Electric Power Steering
45 COOLING
FANCooling Fan Mini Relay
46 CRANKPowertrain Control Module
Mini RelayFuses Usage
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control Module
Relays Usage
24 A/C Air Conditioning Clutch
25 HORN Horn
26 FOG LAMP Fog Lamps
28 RUN/CRANK Body Control Module
30 COOLING
FANEngine Cooling Fan
31 PCM CONT ECM
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
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Engine Compartment Fuse Block
(2.0L Supercharged Engine)
Some fuses are in a fuse block in the engine
compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Fuses Usage
1 ECM Engine Control Module
4 RH HDLP Passenger’s Side Headlamp
5 A/C Air Conditioning Clutch Relay
8 ABS Anti-Lock Brake System
9 ECM/ETC Engine Control Module
10 EMISSCanister Purge Solenoid, Mass Air
Flow Sensor, Low Coolant Switch,
Oxygen Sensors
11 IGN Ignition Coils (1,2,3,4)
13 ECM Engine Control Module
14 BOOST Engine Boost Solenoid
15 BACK-UP Back-up Switch
16 INJECTORS Fuel Injectors (Cylinder 1, 2, 3, 4)
18 LH HDLP Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 RADIO Radio
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Fuses Usage
22 ABS Anti-Lock Brake System
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABS Anti-Lock Brake System
41 IP BATT2 Body Control Module
43 EPS Electric Power Steering
44 COOLING
FAN 2Cooling Fan Mini Relay
45 COOLING
FAN 1Cooling Fan Mini Relay
46 CRANK Crank
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control ModuleRelays Usage
24 A/C CLUTCH Air Conditioning Clutch
25 HORN Horn
27 AFTER
COOLER PUMPAfter Cooler Pump
28 RUN/CRANK Body Control Module
29 POWERTRAINPowertrain
30 COOLING
FAN 1Engine Cooling Fan
31 ECM CONT Starter Solenoid
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
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Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeeRecommended Fluids and
Lubricants on page 6-14for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a
Use Refrigerant Oil, R134a Systems0.9 lbs. 0.41 kg
Cooling System 6.9 quarts 6.5 L
Engine Oil with Filter
2.2L L4
2.0L Supercharged4.0 quarts
6.75 quarts4.8 L
6.4 L
Fuel Tank 13.5 gallons 50.5 L
Transaxle
Manual
Five-Speed Automatic
VTi Variable1.8 quarts
4.2 quarts
6.9 quarts1.7 L
4.0 L
6.5 L
Wheel Nut Torque 92 lb ft 125Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual. Recheck uid level after lling.
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Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Maintenance Requirements
Notice:Maintenance intervals, checks, inspections,
replacement parts and recommended uids and
lubricants as prescribed in this manual are
necessary to keep your vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance may not be covered by
warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance is
important. Improper vehicle maintenance can even
affect the quality of the air we breathe. Improper uid
levels or the wrong tire ination can increase the level of
emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good condition,
be sure to maintain your vehicle properly.
Using Your Maintenance Schedule
We at Saturn want to help you keep your vehicle in good
working condition. But we do not know exactly how
you will drive it. You may drive very short distances only
a few times a week. Or you may drive long distances
all the time in very hot, dusty weather. You may
use your vehicle in making deliveries. Or you may drive
it to work, to do errands or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your Saturn retailer.
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This schedule is for vehicles that:
carry passengers and cargo within recommended
limits. You will nd these limits on the tire and
loading information label. SeeLoading Your Vehicle
on page 4-33.
are driven on reasonable road surfaces within legal
driving limits.
use the recommended fuel. SeeGasoline Octane
on page 5-5.
The services inScheduled Maintenance on page 6-4
should be performed when indicated. SeeAdditional
Required Services on page 6-6andMaintenance
Footnotes on page 6-8for further information.
{CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you
can be seriously injured. Do your own
maintenance work only if you have the
required know-how and the proper tools and
equipment for the job. If you have any doubt,
see your GM Goodwrench dealer to have a
qualied technician do the work.Some maintenance services can be complex. So,
unless you are technically qualied and have the
necessary equipment, you should have your Saturn
retailer do these jobs.
When you go to your Saturn retailer for your service
needs, you will know that Saturn-trained and supported
service technicians will perform the work using
genuine Saturn parts.
If you want to get service information, seeService
Publications Ordering Information on page 7-10.
Owner Checks and Services on page 6-9tells you what
should be checked, when to check it and what you
can easily do to help keep your vehicle in good
condition.
The proper replacement parts, uids and lubricants to
use are listed inRecommended Fluids and Lubricants
on page 6-14andNormal Maintenance Replacement
Parts on page 6-16. When your vehicle is serviced,
make sure these are used. All parts should be replaced
and all necessary repairs done before you or anyone
else drives the vehicle. We recommend the use of
genuine Saturn parts.
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Maintenance Footnotes
†The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle’s useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
(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 drum brake linings for wear or cracks.
Inspect other brake parts, including drums, wheel
cylinders, calipers, parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear.
(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 blade inserts 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 air bag
coverings, and have them repaired or replaced. (The air
bag system does not need regular maintenance.)
(f)Lubricate all key lock cylinders, door hinges and
latches, hood hinges and latches, glove box hinges,
sunroof (if equipped) and any folding seat hardware.
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.
(g)Check system for interference or binding and
for damaged or missing parts. Replace parts as needed.
Replace any components that have high effort or
excessive wear. Do not lubricate accelerator or cruise
control cables.
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(h)Change automatic transaxle or VTi variable transaxle
uid and lter if the vehicle is mainly driven under one
or more of these conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.
(i)Drain, ush and rell cooling system. See Engine
Coolant on page 5-26for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and ller neck.
Pressure test the cooling system and pressure cap.
(j)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired and
the uid level checked. Add uid if needed.
(k)Or every 12 months, whichever occurs rst. If you
drive regularly under dusty conditions, the lter may
require replacement more often.Owner Checks and Services
These owner checks and services should be performed
at the intervals specied to help ensure the safety,
dependability and emission control performance of your
vehicle. Your Saturn retailer can assist you with these
checks and services.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-14.
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While we hope you never have the occasion to use our
service, it is added security while traveling for you
and your family. Remember we are only a phone call
away. Saturn Roadside Assistance: 1-800-553-6000;
text telephone (TTY) users, call 1-800-833-6000.
Saturn reserves the right to limit services or
reimbursement to an owner or driver when, in Saturn’s
judgment, the claims become excessive in frequency
or type of occurrence.
Roadside Assistance is not part of or included in the
coverage provided by the New Vehicle Limited Warranty.
Saturn reserves the right to make any changes or
discontinue the Roadside Assistance program at any
time without notication.
Canadian Roadside Assistance
Vehicles purchased in Canada have an extensive Saturn
Roadside Assistance program accessible from anywhere
in Canada or the United States. Please refer to the
Warranty and Owner Assistance Information book.
Vehicle Data Collection and Event
Data Recorders
Your vehicle, like other modern motor vehicles, has a
number of sophisticated computer systems that monitor
and control several aspects of the vehicle’s performance.
Your vehicle uses on-board vehicle computers to monitor
emission control components to optimize fuel economy,
to monitor conditions for air bag deployment and, if so
equipped, to provide anti-lock braking and to help the
driver control the vehicle in difficult driving situations.
Some information may be stored during regular
operations to facilitate repair of detected malfunctions;
other information is stored only in a crash or near crash
event by computer systems commonly called event data
recorders (EDR).
In a crash or near crash event, computer systems, such
as the Air Bag Sensing and Diagnostic Module (SDM) in
your vehicle may record information about the condition
of the vehicle and how it was operated, such as engine
speed, brake applications, throttle position, vehicle
speed, safety belt usage, air bag readiness, air bag
performance data, and the severity of a collision.
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Service Publications Ordering
Information
Service Manuals
A variety of publications are available to you. Saturn
service manuals are written for trained technicians, and
in some cases, specialized tools and equipment are
necessary to complete certain repairs. However,
the manuals are available to owners who either have
the training, or wish to gain a greater understanding of
the technical aspect of their Saturn.
For additional publications information or to order
publications, call toll free 1-800-2-SATURN or visit
win.wallace.com/saturn to order on-line.
In Canada, Saturn service manuals are available by
calling toll free 1-800-551-4123.
Owner Publications
Information on how to obtain product bulletins and as
described below is applicable only in the fty U.S. states
and the District of Columbia, and only for cars and
light trucks with a GVWR less than 10,000 pounds
(4 536 kg). Copies of individual bulletins are also at your
participating Saturn retailer. You can ask to see them.
In Canada, information relating to product service bulletins
can be obtained by contacting your Saturn retailer.
Service Bulletins
Saturn regularly sends its retailers useful service
bulletins about Saturn products. Saturn monitors product
performance in the eld. We then prepare bulletins for
servicing our products better. You can get these
bulletins, too.
Bulletins cover various subjects. Some pertain to the
proper use and care of your vehicle. Some describe
costly repairs. Others describe inexpensive repairs
which, if done on time with the latest parts, may avoid
future costly repairs.
Some bulletins tell a technician how to repair a new or
unexpected condition. Others describe a quicker
way to x your vehicle. They can help a technician
service your vehicle better.
Most bulletins apply to conditions affecting a small
number of vehicles. Your Saturn retailer or a qualied
technician may have to determine if a specic
bulletin applies to your vehicle. To order Saturn bulletins,
call Saturn Publications at 1-800-2-SATURN or visit
win.wallace.com/saturn to order on-line.
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