engine SATURN ION 2005 Owners Manual

Fuses Usage
17 Fog Lamp
18 Driver’s Side Headlamp
19 Windshield Wiper
20 Horn
21Entertainment, Premium Radio
Amplier
22Anti-lock Brake System, Traction
Control Module
23 Rear Defogger
38 Starter/Ignition
39 Body Control Module 1
40Anti-lock Brake System, Traction
Control Module
41 Body Control Module 2
42 Not Used
43 Electric Power Steering
44 Air Pump Relay Fuse
45 Cooling Fan
46 Crank
47 Body Control Module 1A
48 Body Control Module (IGN 3)Relays Usage
24 Air Conditioning Clutch
25 Horn
26 Fog Lamps
27 Air Solenoid
28 Body Control Module
29 Powertrain
30 Engine Cooling Fan
31 Engine Control Module
32 Wiper System 1
33 Wiper System 2
34 Rear Window Defogger
Diodes Usage
35
§Air Conditioning Diode
36
§Not Used
37
§Wiper Diode
Miscellaneous Usage
49 Fuse Puller
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2.0L L4 Supercharged Engine
Fuses Usage
1 Engine Control Module
2 Not Used
3 Not Used
4 Passenger’s Side Headlamp
5 Air Conditioning
6 Not Used
7 Not Used
8Anti-lock Brake System, Traction
Control Module
9 Engine Control Module
Fuses Usage
10Canister Purge Solenoid, Canister
Vent Solenoid, Low Coolant Switch,
Oxygen Sensors
11Electric Ignition Control Module,
Charging System, Neutral Stop
Back-Up Switch
12 Not Used
13 Engine Control Module
14 Boost
15 PRNDL, Back-up Switch
16 Fuel Injectors
17 Not Used
18 Driver’s Side Headlamp
19 Windshield Wiper
20 Horn
21Entertainment, Premium Radio
Amplier
22Anti-lock Brake System, Traction
Control Module
23 Rear Defogger
38 Starter/Ignition
39 Body Control Module 1
40Anti-lock Brake System, Traction
Control Module
41 Body Control Module 2
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Fuses Usage
42 Not Used
43 Electric Power Steering
44 Cooling Fan 2
45 Cooling Fan 1
46 Crank
47 Body Control Module 1A
48 Body Control Module (IGN 3)
Relays Usage
24 Air Conditioning Clutch
25 Horn
26 Not Used
27 After Cooler Pump
28 Starter/Crank
29 Powertrain
30 Engine Cooling Fan 1
31 Engine Control Module
32 Wiper System 1
33 Wiper System 2
34 Rear Window Defogger
Diodes Usage
35
§Air Conditioning Diode
36
§Not Used
37
§Wiper Diode
Miscellaneous Usage
49 Fuse Puller
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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 0.9 lbs 0.41 kg
Cooling System 7.9 quarts 7.5 L
Intercooler System (2.0L L4 Supercharged) 2.0 quarts 1.88 L
Engine Oil with Filter
2.2L L4 Engine 5.0 quarts 4.7 L
2.0L L4 Supercharged Engine 6.0 quarts 5.7 L
Fuel Tank 13.5 gallons 50.5 L
Transaxle
Manual 1.8 quarts 1.7 L
Automatic 6.9 quarts 6.6 L
Wheel Nut Torque 92 ft-lb 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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Engine Specications
Engine VIN Code Transaxle Spark Plug Gap
2.2L L4 (L61) FManual
Automatic0.045 inches (1.1 mm)
2.0L L4 Supercharged P Manual 0.039 inches (1.0 mm)
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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 the 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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If you want to purchase service information, seeService
Publications Ordering Information on page 7-9.
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.
Scheduled Maintenance
When the CHG OIL message in the message center
comes on, it means that service is required for
your vehicle. SeeChange Engine Oil Message on
page 3-41. Have your vehicle serviced as soon
as possible within the next 600 miles (1 000 km). It is
possible that, if you are driving under the best
conditions, the engine oil life system may not indicate
that vehicle service is necessary for over a year.
However, your engine oil and lter must be changed at
least once a year and at this time the system mustbe reset. Your Saturn retailer has Saturn-trained service
technicians who will perform this work using genuine
Saturn parts and reset the system.
If the engine oil life system is ever reset accidentally,
you must service your vehicle within 3,000 miles
(5 000 km) since your last service. Remember to reset
the oil life system whenever the oil is changed. See
Engine Oil Life System on page 5-20for information on
the Engine Oil Life System and resetting the system.
When the CHG OIL message appears, certain services,
checks, and inspections are required. Required
services are described in the following for
“MaintenanceI” and “MaintenanceII.” Generally, it is
recommended that your rst service be MaintenanceI,
your second service be MaintenanceII, and that you
alternate MaintenanceIand MaintenanceIIthereafter.
However, in some cases, MaintenanceIImay be
required more often.
MaintenanceI— Use MaintenanceIif the CHG OIL
message comes on within 10 months since the
vehicle was purchased or MaintenanceIIwas
performed.
MaintenanceII— Use MaintenanceIIif the previous
service performed was MaintenanceI. Always use
MaintenanceIIwhenever the message comes on
10 months or more since the last service or if the
message has not come on at all for one year.
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-15. Reset oil life
system. SeeEngine Oil Life System on page 5-20.An Emission Control
Service.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-22.See footnote (l).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 5-65and “Tire Wear Inspection” inAt Least Once a Month
on page 6-10.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels. If you have the 2.0L
L4 supercharged engine, check intercooler uid level. Add uid as needed.••
Perform any needed additional services. See “Additional Required Services” in
this section.••
Inspect suspension and steering components.See footnote (b).•
Inspect engine cooling system.See footnote (c).•
Inspect wiper blades.See footnote (d).•
Inspect restraint system components.See footnote (e).•
Lubricate body components.See footnote (f).•
Replace passenger compartment air lter.See footnote (k).•
Inspect throttle system.See footnote (g).•
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Additional Required Services
The following services should be performed at the rst maintenance service (IorII) after the indicated miles
(kilometers) shown for each item.
Additional Required Services
Service and Miles (Kilometers)25,000
(41 500)50,000
(83 000)75,000
(125 000)100,000
(166 000)125,000
(207 500)150,000
(240 000)
Inspect fuel system for damage
or leaks.• •••••
Inspect exhaust system for loose or
damaged components.• •••••
Replace engine air cleaner lter. See
Engine Air Cleaner/Filter on page 5-22.•••
Change automatic transaxle uid
(severe service).See footnote (h).•••
Change automatic transaxle uid
(normal service).•
Replace spark plugs.
An Emission Control Service.•
Replace engine fuel lter.An Emission
Control Service. See footnote †.•
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Additional Required Services (cont’d)
Service and Miles (Kilometers)25,000
(41 500)50,000
(83 000)75,000
(125 000)100,000
(166 000)125,000
(207 500)150,000
(240 000)
Engine cooling system service (or every
ve years, whichever occurs rst).
An Emission Control Service.
See footnote (i).•
Except 2.0L L4 Supercharged engine:
Inspect engine accessory drive belt.
An Emission Control Service.
See footnote (m).•
2.0L L4 Supercharged engine only:
Inspect engine accessory drive belt.
An Emission Control Service.
See footnote (m).•••
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