engine SATURN L-SERIES 2004 Manual PDF

Cooling System
When you decide it is safe to lift the hood, here is what
you will see:
A. Coolant Surge Tank with Pressure Cap
B. Electric Engine Fan{CAUTION:
An electric engine cooling fan under the hood
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.
If the coolant inside the coolant surge tank is boiling, do
not do anything else until it cools down. The vehicle
should be parked on a level surface.
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The coolant level should be at the COLD line (surge
tank seam). If it is not, you may have a leak at the
radiator hoses, heater hoses, radiator, water pump or
somewhere else in the cooling system.
{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 fans are running.
If the engine is overheating, both fans should be
running. If they are 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 may
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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How to Add Coolant to the Coolant
Surge Tank
Notice:This vehicle has a specic coolant ll
procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level isn’t at the FULL COLD mark, add a
50/50 mixture ofclean, drinkable waterand DEX-COOL
®
coolant at the coolant surge tank, but be sure the
cooling system, including the coolant surge tank
pressure cap, is cool before you do it. SeeEngine
Coolant on page 5-23for more information.
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the coolant
surge tank pressure cap — even a little — they
can come out at high speed.
CAUTION: (Continued)
CAUTION: (Continued)
Never turn the cap when the cooling system,
including the coolant surge tank pressure cap,
is hot. Wait for the cooling system and coolant
surge tank pressure cap to cool if you ever
have to turn the pressure cap.
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{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.
Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
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1. You can remove the coolant surge tank pressure
cap when the cooling system, including the coolant
surge tank pressure cap and upper radiator
hose, is no longer hot. Turn the pressure cap slowly
counterclockwise (left) about one-quarter of a
turn. If you hear a hiss, wait for that to stop. This
will allow any pressure still left to be vented out the
discharge hose.
2. Then keep turning the pressure cap slowly, and
remove it.
3. Fill the coolant surge tank with the proper
DEX-COOL
®coolant mixture, to the COLD line.4. With the coolant surge tank pressure cap off, start
the engine and let it run until you can feel the upper
radiator hose getting hot. Watch out for the
engine cooling fans.
By this time, the coolant level inside the coolant
surge tank may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
to the coolant surge tank until the level reaches the
COLD line.
5. Then replace the pressure cap. Be sure the
pressure cap is hand-tight.
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Check the level in the surge tank when the cooling
system has cooled down. If the coolant is not at the
proper level, repeat Steps 1 through 3 and reinstall the
pressure cap. If the coolant isn’t at the proper level when
the system cools down again, see your retailer.
Power Steering Fluid
The power steering uid reservoir is located toward the
front of the engine compartment on the driver’s side
of the vehicle. SeeEngine Compartment Overview on
page 5-12for more information on location.
When to Check Power Steering Fluid
It is not necessary to regularly check power steering uid
unless you suspect there is a leak in the system or
you hear an unusual noise. A uid loss in this system
could indicate a problem. Have the system inspected
and repaired. SeeEngine Compartment Overview
on page 5-12for reservoir location.
How to Check Power Steering Fluid
Turn the key off, let the engine compartment cool down,
wipe the cap and the top of the reservoir clean, then
unscrew the cap and wipe the dipstick with a clean rag.
Replace the cap and completely tighten it. Then remove
the cap again and look at the uid level on the dipstick.
The level should be at the “C” mark. If necessary, add
only enough uid to bring the level up to the mark.
What to Use
To determine what kind of uid to use, see
Recommended Fluids and Lubricants on page 6-12.
Always use the proper uid. Failure to use the proper
uid can cause leaks and damage hoses and seals.
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Windshield Washer Fluid
What to Use
When you need windshield or rear window (wagon
models) washer uid be sure to read the instructions
before use. If you will be operating your vehicle in
an area where the temperature may fall below freezing,
use a uid that has sufficient protection against
freezing.
Adding Windshield Washer Fluid
Open the cap with the
washer uid symbol
printed on it and add
washer uid until the tank
is full.Notice:
When using concentrated washer uid, follow
the manufacturer’s instructions for adding
water.
Do not mix water with ready-to-use washer uid.
Water can cause the solution to freeze and
damage your washer uid tank and other parts
of the washer system. Also, water does not
clean as well as washer uid.
Fill your washer uid tank only three-quarters
full when it is very cold. This allows for
expansion if freezing occurs, which could
damage the tank if it is completely full.
Do not use engine coolant (antifreeze) in your
windshield washer. It can damage your washer
system and paint.
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Brakes
Brake Fluid
Your brake master cylinder
reservoir is lled with
DOT-3 brake uid. See
Engine 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. If it is, you
should have your brake system xed, since a leak
means that sooner or later your brakes will not work
well, or will not work at all.So, it is not a 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 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 3-30.
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What to Add
When you do need brake uid, use only DOT-3 brake
uid. Use new brake uid from a sealed container
only. SeeRecommended Fluids and Lubricants on
page 6-12.
Always clean the brake uid reservoir cap and the area
around the cap before removing it. This will help
keep dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in your brake
system, your brakes may not work well, or
they may not even work at all. This could
cause a crash. Always use the proper brake
uid.Notice:
Using the wrong uid can badly damage brake
system parts. For example, just a few drops of
mineral-based oil, such as engine oil, in your
brake system can damage brake system parts so
badly that they will have to be replaced. Do not
let someone put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged. Be
careful not to spill brake uid on your vehicle. If
you do, wash it off immediately. SeeAppearance
Care on page 5-82.
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Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your vehicle
was designed and tested with top-quality brake parts.
When you replace parts of your braking system — for
example, when your brake linings wear down and you
need new ones put in — be sure you get new approved
Saturn replacement parts. If you do not, your brakes may
no longer work properly. For example, if someone puts in
brake linings that are wrong for your vehicle, the balance
between your front and rear brakes can change — for the
worse. The braking performance you have come to
expect can change in many other ways if someone puts
in the wrong replacement brake parts.
Battery
Your new vehicle comes with a maintenance free
ACDelco®battery. When it is time for a new battery, get
one that has the replacement number shown on the
original battery’s label. We recommend an ACDelco
®
battery. SeeEngine Compartment Overview on
page 5-12for battery location.
Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
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