light SATURN ION 2005 Repair Manual

Brake Wear
Your vehicle has front disc brakes and may have rear
drum brakes or rear disc brakes.
Disc brake pads have built-in wear indicators that make
a high-pitched warning sound when the brake pads
are worn and new pads are needed. The sound
may come and go or be heard all the time your vehicle
is moving, except when you are pushing on the
brake pedal rmly.
{CAUTION:
The brake wear warning sound means that
soon your brakes will not work well. That
could lead to an accident. When you hear the
brake wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.
Some driving conditions or climates may cause a brake
squeal when the brakes are rst applied or lightly
applied. This does not mean something is wrong with
your brakes.Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to Saturn specications.
The rear drum brakes do not have wear indicators, but
if you ever hear a rear brake rubbing noise, have
the rear brake linings inspected immediately. Also, the
rear brake drums should be removed and inspected
each time the tires are removed for rotation or changing.
When you have the front brake pads replaced, have
the rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.Brake Pedal Travel
See your retailer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your
brakes adjust for wear. If you rarely make a moderate
or heavier stop, then your brakes might not adjust
correctly. If you drive in that way, then — very
carefully — make a few moderate brake stops about
every 1,000 miles (1 600 km), so your brakes will adjust
properly.
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Jump Starting
If your vehicle’s battery has run down, you may want to
use another vehicle and some jumper cables to start
your vehicle. Be sure to use the following steps 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 are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not 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 the accessory power outlet. Turn off
the radio and all lamps that are not needed. This
will avoid sparks and help save both batteries. And
it could save the radio!
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4. Open the hoods and locate 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 (+) and
a remote negative (−) jump starting terminal.
The remote positive (+) terminal is located on the
engine compartment fuse block, under a red
cap. SeeEngine Compartment Overview on
page 5-12for more information on location.
The remote negative (−) ground terminal is a bolt
located under the metal frame that supports
the radiator. It is at the front of the engine
compartment, on the driver’s side of the vehicle,
and is marked with a label that says GND (−).
{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 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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Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.
Cold Ination Pressure:The amount of air pressure in
a tire, measured in pounds per square inch (psi) or
kilopascals (kPa) before a tire has built up heat
from driving. SeeInation - Tire Pressure on page 5-63.
Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation (DOT) motor vehicle
safety standards. The DOT code includes the Tire
Identication Number (TIN), an alphanumeric designator
which can also identify the tire manufacturer, production
plant, brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-29.GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-29.
GAWR RR:Gross Axle Weight Rating for the rear axle,
seeLoading Your Vehicle on page 4-29.
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.
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 lbs (68 kg).
SeeLoading Your Vehicle on page 4-29.
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Occupant Distribution:Designated seating positions.
Outward Facing Sidewall:The side of an
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 5-63andLoading Your Vehicle on page 4-29.
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.
Rim:A metal support for a tire and upon which the tire
beads are seated.
Sidewall:The portion of a tire between the tread and
the bead.
Speed Rating:An alphanumeric code assigned to a
tire indicating the maximum speed at which a tire
can operate.Traction:The friction between the tire and the road
surface. The amount of grip provided.
Tread:The portion of a tire that comes into contact
with the road.
Treadwear Indicators:Narrow bands, sometimes
called “wear bars,” that show across the tread of a tire
when only 1/16 inch (1.6 mm) of tread remains. See
When It Is Time for New Tires on page 5-66.
UTQGS (Uniform Tire Quality Grading Standards):A
tire information system that provides consumers with
ratings for a tire’s traction, temperature, and treadwear.
Ratings are determined by tire manufacturers using
government testing procedures. The ratings are molded
into the sidewall of the tire. SeeUniform Tire Quality
Grading on page 5-68.
Vehicle Capacity Weight:The number of designated
seating positions multiplied by 150 lbs (68 kg) plus
the rated cargo load. SeeLoading Your Vehicle
on page 4-29.
Vehicle Maximum Load on the Tire:Load on an
individual tire due to curb weight, accessory weight,
occupant weight, and cargo weight.
Vehicle Placard:A label permanently attached to a
vehicle showing the vehicle’s capacity weight and
the original equipment tire size and recommended
ination pressure. See “Tire and Loading Information
Label” underLoading Your Vehicle on page 4-29.
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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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They can all be hazardous — some more than
others — and they can all damage the vehicle, too.
Do not use any of these products unless this manual
says you can. In many uses, these will damage the
vehicle:
Alcohol
Laundry Soap
Bleach
Reducing Agents
Cleaning the Inside of Your Vehicle
Your vehicle’s interior will continue to look its best if
it is cleaned often. Although not always visible, dust and
dirt can accumulate on your upholstery. Dirt can
damage carpet, fabric, leather, and plastic surfaces.
Regular vacuuming is recommended to remove particles
from your upholstery. It is important to keep your
upholstery from becoming and remaining heavily soiled.
Soils should be removed as quickly as possible. Your
vehicle’s interior may experience extremes of heat
that could cause stains to set rapidly.
Lighter colored interiors may require more frequent
cleaning. Use care because newspapers and garments
that transfer color to your home furnishings may also
transfer color to your vehicle’s interior.When cleaning your vehicle’s interior, only use cleaners
specically designed for the surfaces being cleaned.
Permanent damage may result from using cleaners on
surfaces for which they were not intended. Use glass
cleaner only on glass. Remove any accidental over-spray
from other surfaces immediately. To prevent over-spray,
apply cleaner directly to the cleaning cloth.
Notice:If you use abrasive cleaners when cleaning
glass surfaces on your vehicle, you could scratch
the glass and/or cause damage to the rear window
defogger. When cleaning the glass on your
vehicle, use only a soft cloth and glass cleaner.
Many cleaners contain solvents that may become
concentrated in your vehicle’s breathing space. Before
using cleaners, read and adhere to all safety
instructions on the label. While cleaning your vehicle’s
interior, maintain adequate ventilation by opening
your vehicle’s doors and windows.
Dust may be removed from small buttons and knobs
using a small brush with soft bristles.
Your GM dealer has a product for cleaning your
vehicle’s glass. Should it become necessary, you can
also obtain a product from your GM dealer to remove
odors from your vehicle’s upholstery.
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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 Cleaner Cleans vinyl.
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.
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 EliminatorOdorless spray odor
eliminator used on fabrics,
vinyl, leather, and carpet.
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Instrument Panel Fuse Block
Some fuses are in a fuse block on the driver’s side of
the vehicle, near the driver’s right leg. Loosen the screw
on the cover and remove the cover.
Fuses Usage
FUEL PUMP Fuel Pump Relay
BCM ELECTIgnition Switch, Body Control
Module (BCM)
BCM (PWR) Entry Control, Trunk Release
DASH Instrument Panel, Dimming Switch
LIGHTER Cigar Lighter
PARK Headlamp Switch
CLUSTER Instrument Panel Cluster
PWR
WINDOWSPower Window Switches
STOP Stoplamp (Brake) Switch
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Fuses Usage
HVAC Climate Control
CRUISECruise Control Module, Clutch Start
Switch
AIR BAGAirbags, Sensing and Diagnostic
Module (SDM)
WIPER SWWindshield Wipers and Washers,
Transaxle Shift Lock Control Switch
RADIO
(BATT1)Radio Receiver, Entertainment
Memory
ONSTAREntertainment, Mobile
Communications, OnStar
®
RADIO (ACC) Radio Receiver, Entertainment
IGN SW Ignition Switch
EPS Cruise Control Switches, EPS Unit
PWR OUTLET Auxiliary Power Outlet
SUN ROOF Power Sunroof, OnStar Mirror
Relay Usage
ALC/PARK
RELAYOnStar®, Radio, Instrument Panel
Cluster, Body Control Module (Entry
Control), Cigar Lighter, Headlamp
Switch, License Lamp
FUEL PUMP
RELAYFuel Pump
ACC RELAYPower Windows, Sunroof, Radio,
Wiper/Washer Switch, Accessory
Power Outlet
RUN RELAYClimate Control (HVAC Blower,
Control Heads)
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