service SATURN ION 2007 Workshop Manual

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. SeeRecommended Fluids
and Lubricants on page 402for 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 308for more information.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is
designed to remain in your vehicle for ve years or
150,000 miles (240 000 km), whichever occurs
rst, if you add only DEX-COOL
®extended
life coolant.The following explains your cooling system and
how to add coolant when it is low. If you have
a problem with engine overheating, seeEngine
Overheating on page 297.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to
−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as
they should.
Notice:Using coolant other than DEX-COOL
®
may cause premature engine, heater core, or
radiator corrosion. In addition, the engine
coolant may require changing sooner, at the
rst maintenance service after each
30,000 miles (50 000 km) or 24 months,
whichever occurs rst. Any repairs would not
be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your
vehicle.
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If No Steam Is Coming From Your
Engine
If you get an engine overheat warning with no
warning messages, but see or hear no steam, the
problem may not be too serious. Sometimes
the engine can get a little too hot when you:
Climb a long hill on a hot day.
Stop after high-speed driving.
Idle for long periods in traffic.
Tow a trailer.
If you get the overheat warning with no sign of
steam, try this for a minute or so:
1. If you have an air conditioner and it is on, turn
it off.
2. Turn on your heater to full hot at the highest
fan speed and open the windows as
necessary.
3. Try to minimize engine load. If you are in a
traffic jam, shift to NEUTRAL (N); otherwise,
shift to the highest gear possible while driving.If you no longer have the overheat warning, you
can drive. Just to be safe, drive slower for
about 10 minutes. If the warning does not come
back on, you can drive normally.
If the warning continues and you have not
stopped, pull over, stop, and park your vehicle
right away.
If there is still no sign of steam, you can idle the
engine for three minutes while you are parked.
If you still have the warning, turn off the engine
and get everyone out of the vehicle until it
cools down.
You may decide not to lift the hood but to get
service help right away.
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{CAUTION:
Heater and radiator hoses, and other
engine parts, can be very hot. Do not
touch them. If you do, you can be burned.
Do not run the engine if there is a leak.
If you run the engine, it could lose all
coolant. That could cause an engine re,
and you could be burned. Get any leak
xed before you drive the vehicle.
If there seems to be no leak, with the engine on,
check to see if the electric engine cooling fan
is running. If the engine is overheating, the
fan should be running. If it is not, your vehicle
needs service. Turn off the engine.Notice:Engine damage from running your
engine without coolant is not covered by
your warranty.
Notice:Using coolant other than DEX-COOL®
may cause premature engine, heater core,
or radiator corrosion. In addition, the engine
coolant could require changing sooner, at
30,000 miles (50 000 km) or 24 months,
whichever occurs rst. Any repairs would
not be covered by your warranty. Always
use DEX-COOL
®(silicate-free) coolant in
your vehicle.
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Brake Wear
Your vehicle has front disc brakes and 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 the 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.
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8. Now connect the black negative (−) cable to
the negative (−) terminal of the good battery.
Use a remote negative (−) terminal if the
vehicle has one.
Do not let the other end touch anything until
the next step. The other end of the
negative (−) cable does not go to the dead
battery. It goes to a heavy, unpainted
metal engine part or to a remote negative (−)
terminal on the vehicle with the dead
battery.
9. Connect the other end of the negative (−)
cable at least 18 inches (45 cm) away from
the dead battery, but not near engine
parts that move. The electrical connection is
just as good there, and the chance of
sparks getting back to the battery is much
less.
Your vehicle has a remote negative (−)
terminal for this purpose.10. Now start the vehicle with the good battery
and run the engine for a while.
11. Press the unlock button on the Remote
Keyless Entry (RKE) transmitter, if the vehicle
has one, to disarm your security system.
12. Try to start the vehicle that had the dead
battery. If it will not start after a few tries, it
probably needs service.
Notice:If the jumper cables are connected or
removed in the wrong order, electrical
shorting may occur and damage the vehicle.
The repairs would not be covered by your
warranty. Always connect and remove
the jumper cables in the correct order, making
sure that the cables do not touch each other
or other metal.
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Headlamp Aiming
Headlamp aim has been preset at the factory and
should need no further adjustment.
If your vehicle is damaged in an accident, the
headlamp aim may be affected. Aim adjustment to
the low-beam headlamps may be necessary if it
is difficult to see the lane markers (for horizontal
aim), or if oncoming drivers ash their high-beam
headlamps at you (for vertical aim). If you
believe your headlamps need to be re-aimed, we
recommend that you take your vehicle to your
retailer for service.
Bulb Replacement
For the type of bulb to use, seeReplacement
Bulbs on page 326.
For any bulb changing procedure not listed in this
section, contact your retailer.
Halogen Bulbs
{CAUTION:
Halogen bulbs have pressurized gas
inside and can burst if you drop or
scratch the bulb. You or others could be
injured. Be sure to read and follow the
instructions on the bulb package.
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Tires
Your new vehicle comes with high-quality tires
made by a leading tire manufacturer. If you ever
have questions about your tire warranty and where
to obtain service, see your Saturn Warranty
booklet for details. For additional information refer
to the tire manufacturer’s booklet included with
your vehicle.
{CAUTION:
Poorly maintained and improperly
used tires are dangerous.
Overloading your tires can cause
overheating as a result of too much
friction. You could have an air-out and
a serious accident. SeeLoading Your
Vehicle on page 250.
CAUTION: (Continued)
CAUTION: (Continued)

Underinated tires pose the same
danger as overloaded tires. The
resulting accident could cause serious
injury. Check all tires frequently to
maintain the recommended pressure.
Tire pressure should be checked when
your tires are cold. SeeInflation - Tire
Pressure on page 337.
Overinated tires are more likely to be
cut, punctured, or broken by a sudden
impact — such as when you hit a
pothole. Keep tires at the
recommended pressure.
Worn, old tires can cause accidents. If
your tread is badly worn, or if your tires
have been damaged, replace them.
SeeHigh-Speed Operation on page 338for
ination pressure adjustment for high
speed driving.
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If you choose to use winter tires:
Use tires of the same brand and tread type on
all four wheel positions.
Use only radial ply tires of the same size, load
range, and speed rating as your original
equipment tires.
Winter tires with the same speed rating as your
original equipment tires may not be available for H,
V, W and ZR speed rated tires. If you choose
winter tires with a lower speed rating, never
exceed the tire’s maximum speed capability.
Tire Sidewall Labeling
Useful information about a tire is molded into its
sidewall. The examples below show a typical
passenger vehicle tire and a compact spare tire
sidewall.(A) Tire Size:The tire size is a combination of
letters and numbers used to dene a particular
tire’s width, height, aspect ratio, construction type,
and service description. See the “Tire Size”
illustration later in this section for more detail.
Passenger (P-Metric) Tire Example
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(A) Temporary Use Only:The compact spare
tire or temporary use tire has a tread life of
approximately 3,000 miles (5 000 km) and should
not be driven at speeds over 65 mph (105 km/h).
The compact spare tire is for emergency use when
a regular road tire has lost air and gone at.
If your vehicle has a compact spare tire,
seeCompact Spare Tire on page 365andIf a
Tire Goes Flat on page 349.(B) Tire Ply Material:The type of cord and
number of plies in the sidewall and under the tread.
(C) Tire Identication Number (TIN):The letters
and numbers following the DOT (Department of
Transportation) code is the Tire Identication
Number (TIN). The TIN shows the manufacturer
and plant code, tire size, and date the tire
was manufactured. The TIN is molded onto both
sides of the tire, although only one side may have
the date of manufacture.
(D) Maximum Cold Ination Load Limit:
Maximum load that can be carried and the
maximum pressure needed to support that load.
(E) Tire Ination:The temporary use tire or
compact spare tire should be inated to 60 psi
(420 kPa). For more information on tire pressure
and ination seeInation - Tire Pressure on
page 337.
(F) Tire Size:A combination of letters and
numbers dene a tire’s width, height, aspect ratio,
construction type, and service description. The
letter T as the rst character in the tire size means
the tire is for temporary use only.
Compact Spare Tire Example
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(G) TPC Spec (Tire Performance Criteria
Specication):Original equipment tires designed
to GM’s specic tire performance criteria have
a TPC specication code molded onto the sidewall.
GM’s TPC specications meet or exceed all
federal safety guidelines.
Tire Size
The following illustration shows an example of a
typical passenger vehicle tire size.
(A) Passenger (P-Metric) Tire:The United States
version of a metric tire sizing system. The letter P
as the rst character in the tire size means a
passenger vehicle tire engineered to standards set
by the U.S. Tire and Rim Association.
(B) Tire Width:The three-digit number indicates
the tire section width in millimeters from sidewall
to sidewall.(C) Aspect Ratio:A two-digit number that
indicates the tire height-to-width measurements.
For example, if the tire size aspect ratio is
60, as shown in item C of the illustration, it would
mean that the tire’s sidewall is 60 percent as
high as it is wide.
(D) Construction Code:A letter code is used to
indicate the type of ply construction in the tire.
The letter R means radial ply construction;
the letter D means diagonal or bias ply
construction; and the letter B means belted-bias
ply construction.
(E) Rim Diameter:Diameter of the wheel in
inches.
(F) Service Description:These characters
represent the load range and speed rating of the
tire. The load index represents the load carry
capacity a tire is certied to carry. The load index
can range from 1 to 279. The speed rating is
the maximum speed a tire is certied to carry a
load. Speed ratings range from A to Z.
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