light SATURN ION 2004 Repair Manual

Jump Starting
If your battery has run down, you may want to use
another vehicle and some jumper cables to start your
vehicle. Be sure to follow the steps below to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
They contain acid that can burn you.
They contain gas that can explode or ignite.
They contain enough electricity to burn you.
If you do not follow these steps exactly, some or
all of these things can hurt you.
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 aren’t touching
each other. If they are, it could cause a ground
connection you don’t want. You wouldn’t 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
transaxle in PARK (P) or a manual transaxle 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 in the accessory power outlet. Turn off
the radio and all lamps that aren’t needed. This will
avoid sparks and help save both batteries. And it
could save your radio!
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4. Open the hoods and locate the batteries. Find the
positive (+) and negative (−) terminal locations on
each vehicle.
You will not need to access your battery for jump
starting. Your vehicle has a remote positive (+) jump
starting terminal for that purpose. The terminal is
located on the engine compartment fuse block.
SeeEngine Compartment Overview on page 5-12
for more information on location.
{CAUTION:
An electric fan can start up even when the
engine is not running and can injure you.
Keep hands, clothing and tools away from
any underhood electric fan.
{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
ashlight if you need more light.
Be sure the battery has enough water. You do
not need to add water to the ACDelco
®battery
installed in your new vehicle. But if a battery
has ller caps, be sure the right amount of
uid is there. If it is low, add water to take care
of that rst. If you do not, explosive gas could
be present.
Battery uid contains acid that can burn you.
Do not get it on you. If you accidentally get it
in your eyes or on your skin, ush the place
with water and get medical help immediately.
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GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-33.
Intended Outboard Sidewall:The side of an
asymmetrical tire that must always face outward when
mounted on a vehicle.
Kilopascal (kPa):The metric unit for air pressure.
There are 6.9 kPa’s to one psi.
Light Truck (LT-Metric) Tire:A tire used on light duty
trucks and some multipurpose passenger vehicles.
Load Index:An assigned number ranging from 1 to 279
that corresponds to the load carrying capacity of a tire.
Maximum Ination Pressure:The maximum air
pressure to which a cold tire may be inated. The
maximum air pressure is molded onto the sidewall.
Maximum Load Rating:The load rating for a tire at the
maximum permissible ination pressure for that tire.
Maximum Loaded Vehicle Weight:The sum of curb
weight; accessory weight; vehicle capacity weight;
and production options weight.Normal Occupant Weight:The number of occupants a
vehicle is designed to seat multiplied by 150 pounds
(68 kg). SeeLoading Your Vehicle on page 4-33.
Occupant Distribution:Designated seating positions.
Outward Facing Sidewall:The side of a asymmetrical
tire that has a particular side that faces outward
when mounted on a vehicle. The side of the tire that
contains a whitewall, bears white lettering or bears
manufacturer, brand and or model name molding that is
higher or deeper than the same moldings on the
other sidewall of the tire.
Passenger (P-Metric) Tire:A tire used on passenger
cars and some light duty trucks and multipurpose
vehicles.
Recommended Ination Pressure:Vehicle
manufacturer’s recommended tire ination pressure and
shown on the tire placard. SeeInation - Tire Pressure
on page 5-66andLoading Your Vehicle on page 4-33.
Radial Ply tire:A pneumatic tire in which the ply cords
that extend to the beads are laid at 90 degrees to the
centerline of the tread.
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Uniform Tire Quality Grading
Quality grades can be found where applicable on the
tire sidewall between tread shoulder and maximum
section width. For example:
Treadwear 200 Traction AA Temperature A
The following information relates to the system
developed by the United States National Highway
Traffic Safety Administration, which grades tires by
treadwear, traction and temperature performance.
(This applies only to vehicles sold in the United States.)
The grades are molded on the sidewalls of most
passenger car tires. The Uniform Tire Quality Grading
system does not apply to deep tread, winter-type
snow tires, space-saver or temporary use spare tires,
tires with nominal rim diameters of 10 to 12 inches
(25 to 30 cm), or to some limited-production tires.
While the tires available on General Motors passenger
cars and light trucks may vary with respect to these
grades, they must also conform to federal safety
requirements and additional General Motors Tire
Performance Criteria (TPC) standards.
Treadwear
The treadwear grade is a comparative rating based on
the wear rate of the tire when tested under controlled
conditions on a specied government test course.
For example, a tire graded 150 would wear one and
a half (1.5) times as well on the government course as
a tire graded 100. The relative performance of tires
depends upon the actual conditions of their use,
however, and may depart signicantly from the norm
due to variations in driving habits, service practices and
differences in road characteristics and climate.
Traction – AA, A, B, C
The traction grades, from highest to lowest, are AA, A,
B, and C. Those grades represent the tire’s ability
to stop on wet pavement as measured under controlled
conditions on specied government test surfaces of
asphalt and concrete. A tire marked C may have poor
traction performance. Warning: The traction grade
assigned to this tire is based on straight-ahead braking
traction tests, and does not include acceleration,
cornering, hydroplaning, or peak traction characteristics.
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Vehicle Care/Appearance Materials
See your Saturn retailer for more information on
purchasing the following products.
Vehicle Care/Appearance Materials
Description Usage
Polishing Cloth
Wax-TreatedInterior and exterior
polishing cloth.
Tar and Road
Oil RemoverRemoves tar, road oil
and asphalt.
Chrome Cleaner
and PolishUse on chrome or
stainless steel.
White Sidewall
Tire CleanerRemoves soil and black
marks from whitewalls.
Vinyl CleanerCleans vinyl tops,
upholstery and
convertible tops.
Glass CleanerRemoves dirt, grime,
smoke and ngerprints.
Chrome and Wire
Wheel CleanerRemoves dirt and grime
from chrome wheels and
wire wheel covers.
Finish EnhancerRemoves dust,
ngerprints, and surface
contaminants, Spray on
wipe off.
Vehicle Care/Appearance Materials
(cont’d)
Description Usage
Swirl Remover PolishRemoves swirl marks,
ne scratches and other
light surface
contamination.
Cleaner WaxRemoves light scratches
and protects nish.
Foaming Tire Shine
Low GlossCleans, shines and
protects in one easy step,
no wiping necessary.
Wash Wax ConcentrateMedium foaming
shampoo. Cleans and
lightly waxes.
Biodegradable and
phosphate free.
Spot LifterQuickly and easily
removes spots and stains
from carpets, vinyl and
cloth upholstery.
Odor Eliminator
Odorless spray odor
eliminator used on fabrics,
vinyl, leather and carpet.
See your Saturn parts department for these products.
SeeRecommended Fluids and Lubricants on
page 6-14.
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Fuses Usage
FUEL PUMP Fuel Pump Relay
HVAC Climate Control
CLUSTER Instrument Panel Cluster
LIGHTER Cigar Lighter
RADIO
(BATT1)Radio Receiver, Entertainment
Memory
RADIO (ACC) Radio Receiver, Entertainment
SUNROOF Power Sunroof, OnStar Mirror
WIPER SWWindshield Wipers and Washers,
Transaxle Shift Lock Control Switch
DASH Instrument Panel, Dimming Switch
IGN SW Ignition Switch
PARK Headlamp Switch
PWR OUTLET Auxiliary Power OutletFuses Usage
PWR
WINDOWSPower Window Switches
STOP Stoplamp (Brake) Switch
BCM ELECTIgnition Switch, Body Control
Module (BCM)
BMC (PWR) Entry Control, Trunk Release
Relay Usage
RUNClimate Control (HVAC Blower,
Control Heads)
ACCPower Windows, Sunroof, Radio,
Wiper/Washer Switch, Accessory
Power Outlet
FUEL PUMP Fuel Pump
ALC/PARKOnStar, Radio, Instrument Panel
Cluster, Body Control Module
(Entry Control), Cigar Lighter,
Headlamp Switch, License Lamp
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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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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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A
Accessory Power Outlets.................................3-18
Activating the Theft-Deterrent Feature................3-68
Adding Windshield Washer Fluid.......................5-37
Additives, Fuel................................................. 5-6
Add-On Electrical Equipment............................5-95
Adjusting the Speakers
(Balance/Fade)............................3-49, 3-52, 3-58
Air Bag
Readiness Light..........................................3-30
Air Bag Systems.............................................1-50
Adding Equipment to Your
Air Bag-Equipped Vehicle..........................1-58
How Does an Air Bag Restrain?....................1-56
Servicing Your Air Bag-Equipped Vehicle.........1-58
What Makes an Air Bag Inate?....................1-56
What Will You See After an
Air Bag Inates?......................................1-56
When Should an Air Bag Inate?...................1-55
Where Are the Air Bags?..............................1-52
Air Cleaner/Filter, Engine.................................5-22
Airbag Sensing and Diagnostic Module (SDM)......... 7-7
AM ...............................................................3-70
AM-FM Radio.................................................3-47
Antenna, Fixed Mast.......................................3-71
Antenna, XM™ Satellite Radio
Antenna System..........................................3-71Anti-lock Brake System (ABS)............................ 4-6
Anti-Lock Brake, System Warning Light..............3-34
Appearance Care............................................5-87
Care of Safety Belts....................................5-89
Chemical Paint Spotting...............................5-92
Cleaning the Inside of Your Vehicle................5-87
Cleaning the Outside of Your Vehicle..............5-90
Finish Damage............................................5-92
Sheet Metal Damage...................................5-92
Underbody Maintenance...............................5-92
Vehicle Care/Appearance Materials................5-93
Weatherstrips..............................................5-90
Ashtrays........................................................3-19
Audio System(s).............................................3-46
AM-FM Radio.............................................3-47
Care of Your CD Player...............................3-71
Care of Your CDs........................................3-71
Fixed Mast Antenna.....................................3-71
Radio with CD....................................3-50, 3-54
Setting the Time for Radios with
Radio Data Systems (RDS).......................3-47
Setting the Time for Radios without
Radio Data Systems (RDS).......................3-46
Theft-Deterrent Feature................................3-68
Understanding Radio Reception.....................3-70
XM™ Satellite Radio Antenna System............3-71
Automatic Dimming Mirror Operation..........2-38, 2-40
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Automatic Headlamp System............................3-16
Automatic Transaxle........................................2-20
Fluid..........................................................5-24
Operation...................................................2-23
B
Backing Up....................................................4-43
Battery..........................................................5-41
Battery Replacement......................................... 2-8
Battery Run-Down Protection............................3-18
Battery Warning Light......................................3-31
Before Leaving on a Long Trip.........................4-22
Brake
Parking......................................................2-30
System Warning Light..................................3-32
Brake Adjustment............................................5-40
Brake Fluid....................................................5-38
Brake Pedal Travel.........................................5-40
Brake Wear...................................................5-40
Brakes..........................................................5-38
Braking........................................................... 4-6
Braking in Emergencies..................................... 4-8
Break-In, New Vehicle.....................................2-18
Bulb Replacement...........................................5-48
Center High-Mounted Stoplamp (CHMSL)........5-55
Fog Lamps.................................................5-53Bulb Replacement (cont.)
Front Turn Signal and Parking Lamps.............5-53
Front Turn Signal Lamps..............................5-51
Halogen Bulbs............................................5-48
Headlamp Aiming........................................5-47
Headlamps.........................................5-48, 5-50
Replacement Bulbs......................................5-56
Sidemarker Lamps.......................................5-54
Taillamps, Stoplamps and Back-Up Lamps........5-55
Buying New Tires...........................................5-70
C
California Fuel.................................................. 5-6
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-7
Capacities and Specications..........................5-102
Carbon Monoxide...................4-26, 4-39, 2-12, 2-34
Care of
Safety Belts................................................5-89
Your CD Player...........................................3-71
Your CDs ...................................................3-71
Cassette Tape Player Service...........................6-10
CD Messages........................................3-54, 3-67
Center Console Storage Area...........................2-44
Center High-Mounted Stoplamp (CHMSL)...........5-55
Chains, Tires..................................................5-74
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