wheel SATURN RELAY 2005 Service Manual

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of
Your Vehicle..............................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling the Tank..............................................5-8
Filling a Portable Fuel Container.....................5-10
Checking Things Under the Hood....................5-10
Hood Release..............................................5-11
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-13
Engine Oil Life System..................................5-16
Engine Air Cleaner/Filter................................5-18
Automatic Transaxle Fluid..............................5-19
Engine Coolant.............................................5-22
Radiator Pressure Cap..................................5-25
Engine Overheating.......................................5-25
Overheated Engine Protection
Operating Mode........................................5-27
Cooling System............................................5-28
Power Steering Fluid.....................................5-34Windshield Washer Fluid................................5-35
Brakes........................................................5-36
Battery........................................................5-39
Jump Starting...............................................5-40
All-Wheel Drive..............................................5-45
Bulb Replacement..........................................5-47
Halogen Bulbs..............................................5-47
Headlamps and Sidemarker Lamps.................5-47
Front Turn Signal, Parking and Daytime
Running Lamps (DRL)................................5-49
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-49
Replacement Bulbs.......................................5-50
Windshield Wiper Blade Replacement..............5-51
Tires..............................................................5-52
Tire Sidewall Labelling...................................5-53
Tire Terminology and Denitions.....................5-55
Ination - Tire Pressure.................................5-58
Tire Inspection and Rotation...........................5-59
When It Is Time for New Tires.......................5-60
Buying New Tires.........................................5-61
Uniform Tire Quality Grading..........................5-62
Wheel Alignment and Tire Balance..................5-63
Wheel Replacement......................................5-64
Section 5 Service and Appearance Care
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Tire Chains..................................................5-65
Accessory Inator.........................................5-66
If a Tire Goes Flat........................................5-68
Changing a Flat Tire.....................................5-69
Removing the Spare Tire and Tools................5-70
Removing the Flat Tire and Installing the
Spare Tire................................................5-73
Secondary Latch System...............................5-80
Storing a Flat or Spare Tire and Tools............5-82
Compact Spare Tire......................................5-87
Appearance Care............................................5-87
Cleaning the Inside of Your Vehicle.................5-88
Fabric/Carpet...............................................5-89
Leather.......................................................5-90
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-90
Care of Safety Belts......................................5-91
Weatherstrips...............................................5-91
Washing Your Vehicle...................................5-91
Cleaning Exterior Lamps/Lenses.....................5-91
Finish Care..................................................5-92Windshield, Backglass, and Wiper Blades.........5-92
Aluminum Wheels.........................................5-93
Tires...........................................................5-93
Sheet Metal Damage.....................................5-94
Finish Damage.............................................5-94
Underbody Maintenance................................5-94
Chemical Paint Spotting.................................5-94
Vehicle Care/Appearance Materials..................5-95
Vehicle Identication......................................5-96
Vehicle Identication Number (VIN).................5-96
Service Parts Identication Label.....................5-96
Electrical System............................................5-97
Add-On Electrical Equipment..........................5-97
Headlamp Wiring..........................................5-97
Windshield Wiper Fuses................................5-97
Power Windows and Other Power Options.......5-97
Fuses and Circuit Breakers............................5-98
Instrument Panel Fuse Block..........................5-98
Underhood Fuse Block................................5-100
Capacities and Specications........................5-103
Section 5 Service and Appearance Care
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Brake Wear
Your vehicle has four-wheel 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 torque specications.
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 apply the brakes, with or without the
vehicle moving, your brakes adjust for wear.
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All-Wheel Drive
If you have an all-wheel-drive vehicle, be sure to
perform the lubricant checks described in this section.
All-wheel-drive vehicles have two additional systems that
need lubrication.
Transfer Case (Power Transfer Unit)
When to Check Lubricant
Refer to the Maintenance Schedule to determine how
often to check the lubricant. SeeScheduled
Maintenance on page 6-4.
How to Check Lubricant
To get an accurate reading, the vehicle should be on a
level surface.
If the level is below the bottom of the ller plug hole,
located on the transfer case, you will need to add some
lubricant. Add enough lubricant to raise the level to
the bottom of the ller plug hole.
What to Use
Refer to the Maintenance Schedule to determine what
kind of lubricant to use. SeeRecommended Fluids
and Lubricants on page 6-12.
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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.
Tire Terminology and Denitions
Air Pressure:The amount of air inside the tire pressing
outward on each square inch of the tire. Air pressure
is expressed in pounds per square inch (psi) or
kilopascal (kPa).
Accessory Weight:This means the combined weight
of optional accessories. Some examples of optional
accessories are, automatic transmission, power steering,
power brakes, power windows, power seats, and air
conditioning.
Aspect Ratio:The relationship of a tire’s height to
its width.
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How to Check
Use a good quality pocket-type gage to check tire
pressure. You cannot tell if your tires are properly
inated simply by looking at them. Radial tires may look
properly inated even when they are under-inated.
Check the tire’s ination pressure when the tires
are cold. Cold means your vehicle has been sitting
for at least three hours or driven no more than
1 mile (1.6 km).
Remove the valve cap from the tire valve stem. Press
the tire gage rmly onto the valve to get a pressure
measurement. If the cold tire ination pressure matches
the recommended pressure on the Tire and Loading
Information label, no further adjustment is necessary.
If the ination pressure is low, add air until you reach the
recommended amount.
If you overll the tire, release air by pushing on the
metal stem in the center of the tire valve. Re-check the
tire pressure with the tire gage.
Be sure to put the valve caps back on the valve stems.
They help prevent leaks by keeping out dirt and
moisture.
Tire Inspection and Rotation
Tires should be rotated every 5,000 to 8,000 miles
(8 000 to 13 000 km).
Any time you notice unusual wear, rotate your tires as
soon as possible and check wheel alignment. Also
check for damaged tires or wheels. SeeWhen It Is Time
for New Tires on page 5-60andWheel Replacement
on page 5-64for more information.
The purpose of regular rotation is to achieve more
uniform wear for all tires on the vehicle. The rst rotation
is the most important. SeeScheduled Maintenance
on page 6-4.
When rotating your tires, always use the correct rotation
pattern shown here.
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Do not include the compact spare tire in your tire
rotation.
After the tires have been rotated, adjust the front and
rear ination pressures as shown on the Tire and
Loading Information label.
Make certain that all wheel nuts are properly tightened.
See “Wheel Nut Torque” underCapacities and
Specications on page 5-103.
{CAUTION:
Rust or dirt on a wheel, or on the parts to
which it is fastened, can make wheel nuts
become loose after a time. The wheel could
come off and cause an accident. When you
change a wheel, remove any rust or dirt from
places where the wheel attaches to the vehicle.
In an emergency, you can use a cloth or a
paper towel to do this; but be sure to use a
scraper or wire brush later, if needed, to get all
the rust or dirt off. SeeChanging a Flat Tire on
page 5-69.
When It Is Time for New Tires
One way to tell when it is
time for new tires is to
check the treadwear
indicators, which will
appear when your tires
have only 1/16 inch
(1.6 mm) or less of tread
remaining.
You need a new tire if any of the following statements
are true:
You can see the indicators at three or more places
around the tire.
You can see cord or fabric showing through the
tire’s rubber.
The tread or sidewall is cracked, cut or snagged
deep enough to show cord or fabric.
The tire has a bump, bulge or split.
The tire has a puncture, cut or other damage that
cannot be repaired well because of the size or
location of the damage.
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Buying New Tires
To nd out what kind and size of tires you need, look at
the Certication/Tire label or the Tire and Loading
Information label. SeeLoading Your Vehicle on
page 4-31, for examples of the labels and where they
can be found on your vehicle.
The tires installed on your vehicle when it was new had
a Tire Performance Criteria Specication (TPC Spec)
number on each tire’s sidewall. When you get new tires,
GM recommends that you get tires with that same
TPC Spec number. That way your vehicle will continue
to have tires that are designed to give proper
endurance, handling, speed rating, traction, ride and
other things during normal service on your vehicle.
If your tires have an all-season tread design, the TPC
number will be followed by an “MS” (for mud and snow).
If you ever replace your tires with those not having a
TPC Spec number, make sure they are the same
size, load range, speed rating and construction type
(bias, bias-belted or radial) as your original tires.{CAUTION:
Mixing tires could cause you to lose control
while driving. If you mix tires of different sizes
or types (radial and bias-belted tires), the
vehicle may not handle properly, and you
could have a crash. Using tires of different
sizes may also cause damage to your vehicle.
Be sure to use the same size and type tires on
all wheels. It’s all right to drive with your
compact spare temporarily, it was developed
for use on your vehicle. SeeCompact Spare
Tire on page 5-87.
{CAUTION:
If you use bias-ply tires on your vehicle, the
wheel rim anges could develop cracks after
many miles of driving. A tire and/or wheel
could fail suddenly, causing a crash. Use only
radial-ply tires with the wheels on your vehicle.
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Temperature – A, B, C
The temperature grades are A (the highest), B, and C,
representing the tire’s resistance to the generation
of heat and its ability to dissipate heat when tested
under controlled conditions on a specied indoor
laboratory test wheel. Sustained high temperature can
cause the material of the tire to degenerate and
reduce tire life, and excessive temperature can lead to
sudden tire failure. The grade C corresponds to a
level of performance which all passenger car tires must
meet under the Federal Motor Vehicle Safety Standard
No. 109. Grades B and A represent higher levels of
performance on the laboratory test wheel than the
minimum required by law.
Warning: The temperature grade for this tire is
established for a tire that is properly inated and not
overloaded. Excessive speed, underination, or
excessive loading, either separately or in combination,
can cause heat buildup and possible tire failure.
Wheel Alignment and Tire Balance
The tires and wheels on your vehicle were aligned
and balanced carefully at the factory to give you the
longest tire life and best overall performance.
Adjustments to wheel alignment and tire balancing will
not be necessary on a regular basis. However, if
you notice unusual tire wear or your vehicle pulling to
one side or the other, the alignment may need to
be checked. If you notice your vehicle vibrating when
driving on a smooth road, your tires and wheels
may need to be rebalanced. See your retailer for proper
diagnosis.
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Wheel Replacement
Replace any wheel that is bent, cracked or badly rusted
or corroded. If wheel nuts keep coming loose, the
wheel, wheel bolts and wheel nuts should be replaced.
If the wheel leaks air, replace it (except some
aluminum wheels, which can sometimes be repaired).
See your retailer if any of these conditions exist.
Your retailer will know the kind of wheel you need.
Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.
If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new Saturn
original equipment parts. This way, you will be sure to
have the right wheel, wheel bolts and wheel nuts
for your vehicle.{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.
Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-69for more
information.
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