brake SATURN L-SERIES 2005 Workshop Manual

{CAUTION:
Changing a tire can be dangerous. The vehicle
can slip off the jack and roll over or fall on you
or other people. You and they could be badly
injured or even killed. Find a level place to
change your tire. To help prevent the vehicle
from moving:
1. Set the parking brake rmly.
2. Put the shift lever in PARK (P).
3. Turn off the engine and do not restart
while the vehicle is raised.
4. Do not allow passengers to remain in
the vehicle.
To be even more certain the vehicle will not
move, you should put blocks at the front and
rear of the tire farthest away from the one
being changed. That would be the tire, on the
other side, at the opposite end of the vehicle.When you have a flat tire, use the following example as a
guide to assist you in the placement of wheel blocks.
The following information will tell you next how to use
the jack and change a tire.
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{CAUTION:
Incorrect wheel nuts or improperly tightened
wheel nuts can cause the wheel to come loose
and even come off. This could lead to an
accident. Be sure to use the correct wheel
nuts. If you have to replace them, be sure to
get new GM original equipment wheel nuts.
Stop somewhere as soon as you can and have
the nuts tightened with a torque wrench to the
proper torque specication. SeeCapacities
and Specifications on page 5-89for wheel nut
torque specication.
Notice:Improperly tightened wheel nuts can lead
to brake pulsation and rotor damage. To avoid
expensive brake repairs, evenly tighten the wheel
nuts in the proper sequence and to the proper
torque specication. SeeCapacities and
Specifications on page 5-89for the wheel nut torque
specication.13. Tighten the wheel nuts
firmly in a crisscross
sequence, as shown.
14. Lower the jack all the way and remove the jack
from under the vehicle.
15. Tighten the bolts firmly with the wheel wrench.
Notice:Wheel covers will not t on your compact
spare. If you try to put a wheel cover on the compact
spare, you could damage the cover or the spare.
Do not try to put a wheel cover on your compact spare
tire. It will not fit. Store the wheel cover in the trunk
until you have the flat tire repaired or replaced.
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Floor Console Fuse Block
The driver’s side instrument panel is located under the
instrument panel on the driver’s left side.
Use a key or a coin to remove the fuse panel door and
access the fuses and relays.
Fuses Usage
DIMMER Dimmer Switch
IGN 3Left Heated Seat Switch
(If Equipped), Right Heated
Seat Switch (If Equipped), Air
Conditioning, Rear Defogger Relay
DEFOG LED Rear Defog LED
RR COMP Trunk Compartment Lamp
WIPERWindshield Washers and
Wipers (Front)
BTSI/BCM/
MIRRORBrake Transaxle Shift Interlock,
Body Control Module, Power Mirror
RADIOAudio, OnStar
®, Rear Seat DVD
(Option)
Relays Usage
IGN 3 Ignition Switch
REAR DEFOG Rear Defogger
HEADLAMP Headlamps
PARKLAMP Park Lamps
Misc. Usage
FUSE PULLER Fuse Puller
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Fuses Usage
FUEL PUMP Fuel Pump System
RT HEADLAMP Right Headlamps
BRAKE Brake Lamps
IGN 1Instrument Cluster, Coolant Level
Switch, Air Bag, Electronic
PRND321
HAZARDHazard Flasher, HBTT (Headlamp
HI Beam Indicator), I/P Cluster
ABS 2 Anit-Lock Brake System
CONTROLS
IGN 1Cooling Fan Control Module,
Powertrain Control Module,
Transaxle (2.2L L4, If Equipped),
Transaxle Control Module (3.0L V6)
BACK-UP/TURNBackup Lamps, Coolant
Level Switch
CRUISE SW Cruise Control Switch
BCM/ECM/
CRUISEBody Control Module, Engine
Control Module, Cruise Control, ABS
ABS 1 Anit-Lock Brake SystemFuses Usage
ENGINE
CNTL 3 (V6)3.0L V6 Engine
REAR DEFOG Rear Window Defogger
HVAC
BLOWERHigh Blower
IGN 0Park Neutral Position Switch,
Powertrain Control Module
AC Air Conditioning System
CD/DLCAudio, Data Link Connector, (DLC),
Rear Seat DVD (Option)
IGN 1/2 Ignition switch
HORN Horn
CONTROLS B+Powertrain Control Module (2.2L L4,
If Equipped), Engine Control Module
(3.0L V6), Transaxle Control Module
(3.0L V6)
I/P BATT RTPassenger’s Side Instrument Panel
Fuse Block
AUX PWR Power Outlet
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and filter. SeeEngine Oil on page 5-13. Reset oil life system.
SeeEngine Oil Life System on page 5-16.An Emission Control Service.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner filter. If necessary, replace filter. SeeEngine Air
Cleaner/Filter on page 5-17.An Emission Control Service. See footnote †.••
Rotate tires and check inflation pressures and wear. SeeTires on page 5-48.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer fluid levels and add fluid
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 filter.See footnote (k).•
Inspect throttle system.See footnote (g).•
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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 other brake parts, including calipers,
parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear. Inspect power steering lines and
hoses for proper hook-up, binding, leaks, cracks,
chang, etc.
(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 airbag
coverings, and have them repaired or replaced.
(The airbag 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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Engine Coolant Level Check
Check the engine coolant level and add
DEX-COOL®coolant mixture if necessary.
SeeEngine Coolant on page 5-20for further details.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the windshield
washer tank and add the proper fluid if necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your tires and make sure tires are
inflated to the correct pressures. Do not forget to check
your spare tire. SeeTires on page 5-48for further
details. Check to make sure the spare tire is stored
securely. Push, pull and then try to turn the spare tire.
If it moves, tighten it. SeeChanging a Flat Tire on
page 5-62.
At Least Once a Year
Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. SeeParking Brake on page 2-22if necessary.
Do not use the accelerator pedal, and be ready to
turn off the engine immediately if it starts.
3. Try to start the engine in each gear. The starter
should work only in PARK (P) or NEUTRAL (N).
If the starter works in any other position, contact
your retailer for service.
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Automatic Transaxle Shift Lock Control
System Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough
room around the vehicle. It should be parked
on a level surface.
2. Firmly apply the parking brake. SeeParking Brake
on page 2-22if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.3. With the engine off, turn the ignition to RUN, but do
not start the engine. Without applying the regular
brake, try to move the shift lever out of PARK (P)
with normal effort. If the shift lever moves out
of PARK (P), contact your retailer for service.
Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition to OFF in each shift lever position.
•The ignition should turn to OFF only when the shift
lever is in PARK (P).
•The key should come out only in OFF.
Contact your retailer if service is required.
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Parking Brake and Automatic Transaxle
Park (P) Mechanism Check
{CAUTION:
When you are doing this check, your vehicle
could begin to move. You or others could be
injured and property could be damaged. Make
sure there is room in front of your vehicle in
case it begins to roll. Be ready to apply the
regular brake at once should the vehicle begin
to move.Park on a fairly steep hill, with the vehicle facing
downhill. Keeping your foot on the regular brake,
set the parking brake.
•To check the parking brake’s holding ability: With
the engine running and transaxle in NEUTRAL (N),
slowly remove foot pressure from the regular
brake pedal. Do this until the vehicle is held by the
parking brake only.
•To check the PARK (P) mechanism’s holding ability:
With the engine running, shift to PARK (P).
Then release the parking brake followed by the
regular brake.
Contact your retailer if service is required.
Underbody Flushing Service
At least every spring, use plain water to flush any
corrosive materials from the underbody. Take care to
clean thoroughly any areas where mud and other debris
can collect.
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Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name,
part number or specification may be obtained
from your retailer.
Usage Fluid/Lubricant
Engine OilEngine oil which meets GM
Standard GM6094M and displays
the American Petroleum Institute
Certified for Gasoline Engines
starburst symbol. GM Goodwrench
oil meets all the requirements for
your vehicle. To determine the
proper viscosity for your vehicle’s
engine, seeEngine Oil on
page 5-13.
Engine Coolant50/50 mixture of clean, drinkable
water and use only
DEX-COOL
®Coolant. SeeEngine
Coolant on page 5-20.
Hydraulic Brake
SystemDelco Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventOptikleen
®Washer Solvent.
Parking Brake
Cable GuidesChassis Lubricant (GM Part No.
12377985, in Canada 88901242) or
lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Usage Fluid/Lubricant
Power Steering
SystemPower Steering Fluid (Saturn Part
No. 21007583 or GM Part No. U.S.
89021184, in Canada 89021186).
Automatic
TransaxleDEXRON
®-III Automatic
Transmission Fluid. Look for
“Approved for the H-Specification”
on the label.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Hood Latch
Assembly,
Secondary
Latch, Pivots,
Spring Anchor
and Release
PawlLubriplate Lubricant Aerosol (Saturn
Part No. 21038869 or GM Part No.
U.S. 12346293, in Canada 992723)
or lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Hood, Trunk
and Door
HingesMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241, in
Canada 10953474).
Sunroof TrackLubriplate Lubricant Aerosol (Saturn
Part No. 21038869 or GM Part No.
U.S. 12346293, in Canada 992723)
or lubricant meeting requirements of
NLGI #2, Category LB or GC-LB.
Weatherstrip
ConditioningDielectric Silicone Grease (GM Part
No. U.S. 12345579, in Canada
992887).
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