brake SATURN ION 2004 Service Manual

Driving with a Trailer
Towing a trailer requires a certain amount of experience.
Before setting out for the open road, you’ll want to get
to know your rig. Acquaint yourself with the feel of
handling and braking with the added weight of the trailer.
And always keep in mind that the vehicle you are
driving is now a good deal longer and not nearly as
responsive as your vehicle is by itself.
Before you start, check the trailer hitch and platform
(and attachments), safety chains, electrical connector,
lamps, tires and mirror adjustment. If the trailer has
electric brakes, start your vehicle and trailer moving and
then apply the trailer brake controller by hand to be
sure the brakes are working. This lets you check your
electrical connection at the same time.
During your trip, check occasionally to be sure that the
load is secure, and that the lamps and any trailer
brakes are still working.
Following Distance
Stay at least twice as far behind the vehicle ahead as
you would when driving your vehicle without a trailer.
This can help you avoid situations that require
heavy braking and sudden turns.
Passing
You’ll need more passing distance up ahead when
you’re towing a trailer. And, because you’re a good deal
longer when towing a trailer, you’ll need to go much
farther beyond the passed vehicle before you can return
to your lane.
Backing Up
Hold the bottom of the steering wheel with one hand.
Then, to move the trailer to the left, just move that hand
to the left. To move the trailer to the right, move your
hand to the right. Always back up slowly and, if possible,
have someone guide you.
Making Turns
Notice:Making very sharp turns while trailering
could cause the trailer to come in contact with the
vehicle. Your vehicle could be damaged. Avoid
making very sharp turns while trailering.
When you’re turning with a trailer, make wider turns
than normal. Do this so your trailer won’t strike
soft shoulders, curbs, road signs, trees or other objects.
Avoid jerky or sudden maneuvers. Signal well in
advance.
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Turn Signals When Towing a Trailer
When you tow a trailer, your vehicle may need a
different turn signal asher and/or extra wiring. See your
retailer if you need information. The arrows on your
instrument panel will ash whenever you signal a turn or
lane change. Properly hooked up, the trailer lamps
will also ash, telling other drivers you’re about to turn,
change lanes or stop.
When towing a trailer, the arrows on your instrument
panel will ash for turns even if the bulbs on the trailer
are burned out. Thus, you may think drivers behind
you are seeing your signal when they are not. It’s
important to check occasionally to be sure the trailer
bulbs are still working.
Driving on Grades
Notice:Do not tow on steep continuous grades
exceeding 6 miles (9.6 km). Extended, higher
than normal engine and transaxle temperatures may
result and damage your vehicle. Frequent stops
are very important to allow the engine and transaxle
to cool.
Reduce speed and shift to a lower gear before you start
down a long or steep downgrade. If you don’t shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
On a long uphill grade, shift down and reduce your
speed to around 45 mph (70 km/h) to reduce the
possibility of the engine and the transmission
overheating. If your engine does overheat, seeEngine
Overheating on page 5-29.
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Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) for an automatic transaxle, or into gear for
a manual transaxle.
When parking uphill, turn your wheels away from
the curb. When parking downhill, turn your wheels
into the curb.
2. Have someone place chocks behind the trailer
wheels.3. When the chocks are in place, release the regular
brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake and shift into PARK (P) for an
automatic transaxle or REVERSE (R) for a manual
transaxle.
5. Release the regular brakes.
When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
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Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. SeeScheduled Maintenance on
page 6-4for more information. Things that are especially
important in trailer operation are automatic transaxle
uid (don’t overll), engine oil, axle lubricant, drive belt,
cooling system and brake system. Each of these is
covered in this manual, and the Index will help you nd
them quickly. If you’re trailering, it’s a good idea to
review this information before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Engine Cooling When Trailer Towing
Your cooling system may temporarily overheat during
severe operating conditions. SeeEngine Overheating on
page 5-29.
Changing a Tire When Trailer Towing
If you get a at tire while towing a trailer, be sure
to secure the trailer and disconnect it from the vehicle
before changing the tire.
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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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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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A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
B. Engine Oil Fill Location. SeeEngine Oil on
page 5-15.
C. Engine Oil Dipstick Location. SeeEngine Oil on
page 5-15.
D. Brake Master Cylinder. SeeBrakes on page 5-38
andHydraulic Clutch on page 5-25.
E. Remote Positive Terminal Location. SeeJump
Starting on page 5-42.F. Engine Compartment Fuse Block. SeeFuses and
Circuit Breakers on page 5-95.
G. Surge Tank. SeeEngine Coolant on page 5-26.
H. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-37.
Before closing the hood, be sure all ller caps are on
properly.
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A. Engine Oil Dipstick Location. SeeEngine Oil on
page 5-15.
B. Electric Cooling Fan. SeeCooling System on
page 5-32.
C. Engine Oil Fill Location. SeeEngine Oil on
page 5-15.
D. Radiator Pressure Cap. SeeEngine Coolant on
page 5-26.
E. Brake Master Cylinder. SeeBrakes on page 5-38
andHydraulic Clutch on page 5-25.
F. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
G. Engine Compartment Fuse Block. SeeFuses and
Circuit Breakers on page 5-95.
H. Remote Positive Terminal Location. SeeJump
Starting on page 5-42.
I. Surge Tank. SeeCoolant Surge Tank Pressure Cap
on page 5-29.
J. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-37.
Before closing the hood, be sure all ller caps are on
properly.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
Pull out the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it again,
keeping the tip down, and check the level.
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If you do not use your vehicle under any of these
conditions, the uid and lter do not require changing.
Notice:For VTi variable transaxles, use only Saturn
Variable Transaxle Fluid. Using any other uid will
result in transaxle damage. Damage cause by
the use of uid other than Saturn Variable Transaxle
Fluid will not be covered by your warranty.
Notice:For ve-speed automatic transaxles,
use only Saturn T-IV Transaxle Fluid. Using any
other uid will result in transaxle damage. Damage
cause by the use of uid other than Saturn T-IV
Transaxle Fluid will not be covered by your
warranty.Manual Transaxle Fluid
It is not necessary to check the transaxle uid level.
A transaxle uid leak is the only reason for uid loss.
If a leak occurs, take the vehicle to your retailer’s service
department and have it repaired as soon as possible.
You may also have your uid level checked by your
retailer or service center when you have your oil
changed. SeeRecommended Fluids and Lubricants
on page 6-14for 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 5-38for more information.
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Brakes
Brake Fluid
Your brake master cylinder reservoir is lled with DOT-3
brake uid. SeeEngine Compartment Overview on
page 5-12for the location of the reservoir.
There are only two reasons why the brake uid level
in the reservoir might go down. The rst is that the brake
uid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the uid
level goes back up. The other reason is that uid is
leaking out of the brake system or hydraulicclutch system if you have a manual transaxle. If it is,
you should have both systems checked and the
necessary repairs made, since a leak means that sooner
or later your brakes and/or clutch will not work well, or
will not work at all.
So, it isn noa good idea to “top off” your brake uid.
Adding brake uid will not correct a leak. If you add uid
when your linings are worn, then you will have too
much uid when you get new brake linings. You should
add (or remove) brake uid, as necessary, only when
work is done on the brake and/or clutch hydraulic system.
{CAUTION:
If you have too much brake uid, it can spill on
the engine. The uid will burn if the engine is
hot enough. You or others could be burned,
and your vehicle could be damaged. Add brake
uid only when work is done on the brake
hydraulic system.
When your brake uid falls to a low level, your brake
warning light will come on. SeeBrake System Warning
Light on page 3-32.
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