brake SATURN RELAY 2006 Workshop Manual

A. Underhood Fuse Block. SeeUnderhood Fuse Block
on page 5-100.
B. Remote Positive (+) Terminal. SeeJump Starting on
page 5-40.
C. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-36.
D. Radiator Pressure Cap. SeeRadiator Pressure Cap
on page 5-26.
E. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-15.
F. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-35.
G. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-15.
H. Automatic Transaxle Fluid Dipstick. See “Checking
the Fluid Level” underAutomatic Transaxle Fluid
on page 5-21.
I. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-37.
J. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-20.
K. Engine Coolant Recovery Tank. SeeCooling System
on page 5-28.Engine Oil
Checking Engine Oil
It is a good idea to check your engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop. See
Engine Compartment Overview on page 5-12for
the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull out the dipstick and clean it with a paper towel
or cloth, then push it back in all the way. Remove it
again, keeping the tip down, and check the level.
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Wait at least 30 minutes before checking the transaxle
uid level if you have been driving:
When outside temperatures are above 90°F (32°C).
At high speed for quite a while.
In heavy traffic — especially in hot weather.
While pulling a trailer.
To get the right reading, the uid should be at normal
operating temperature, which is 180°F to 200°F
(82°C to 93°C).
Get the vehicle warmed up by driving about 15 miles
(24 km) when outside temperatures are above 50°F
(10°C). If it is colder than 50°F (10°C), you may have to
drive longer.
Checking the Fluid Level
Prepare your vehicle as follows:
1. Park your vehicle on a level place. Keep the engine
running.
2. With the parking brake applied, place the shift lever
in PARK (P).3. With your foot on the brake pedal, move the shift
lever through each gear range, pausing for about
three seconds in each range. Then, position
the shift lever in PARK (P).
4. Let the engine run at idle for three to ve minutes.
Then, without shutting off the engine, follow these
steps:
1. Pull out the dipstick and wipe it with a clean rag or
paper towel.
The automatic transaxle dipstick is located toward
the back of the engine compartment, near the brake
master cylinder reservoir. The dipstick handle is a
red loop. SeeEngine Compartment Overview
on page 5-12for more information on location.
2. Push it back in all the way, wait three seconds, and
then pull it back out again.
3. Check both sides of the dipstick, and read the
lower level. The uid level must be in the
cross-hatched area.
4. If the uid level is in the acceptable range, push the
dipstick back in all the way.
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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 3-40.
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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 6-11.
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. SeeWashing
Your Vehicle on page 5-91.
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.
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{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.
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 Saturn
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.
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{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!
4. Open the hoods and locate the batteries. Find 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 (+) jump
starting terminal for that purpose.
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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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Buying New Tires
GM has developed and matched specic tires for your
vehicle. The original equipment tires installed on
your vehicle, when it was new, were designed to meet
General Motors Tire Performance Criteria Specication
(TPC spec) system rating. If you need replacement
tires, GM strongly recommends that you get tires with
the same TPC Spec rating. This way, your vehicle
will continue to have tires that are designed to give the
same performance and vehicle safety, during normal
use, as the original tires.
GM’s exclusive TPC Spec system considers over a
dozen critical specications that impact the overall
performance of your vehicle, including brake system
performance, ride and handling, traction control, and tire
pressure monitoring performance. GM’s TPC Spec
number is molded onto the tire’s sidewall by the
tire manufacturer. If the tires have an all-season tread
design, the TPC spec number will be followed by an MS
for mud and snow. SeeTire Sidewall Labeling on
page 5-54for additional information.{CAUTION:
Mixing tires could cause you to lose control
while driving. If you mix tires of different sizes,
brands, or types (radial and bias-belted tires),
the vehicle may not handle properly, and you
could have a crash. Using tires of different
sizes, brands, or types may also cause
damage to your vehicle. Be sure to use the
correct size, brand, and type of tires on all
wheels. It is all right to drive with your
compact spare temporarily, as it was
developed for use on your vehicle. See
Compact 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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If you must replace your vehicle’s tires with those that
do not have a TPC Spec number, make sure they
are the same size, load range, speed rating, and
construction type (radial and bias-belted tires) as your
vehicle’s original tires.
Your vehicle’s original equipment tires are listed on the
Tire and Loading Information Label. This label is
attached to the vehicle’s center pillar (B-pillar). See
Loading Your Vehicle on page 4-33, for more information
about the Tire and Loading Information Label and its
location on your vehicle.
Different Size Tires and Wheels
If you add wheels or tires that are a different size than
your original equipment wheels and tires, this may
affect the way your vehicle performs, including its
braking, ride and handling characteristics, stability, and
resistance to rollover. Additionally, if your vehicle
has electronic systems such as, antilock brakes; traction
control; and stability control, the performance of these
systems can be affected.
{CAUTION:
If you add different sized wheels, your vehicle
may not provide an acceptable level of
performance and safety if tires not
recommended for those wheels are selected.
You may increase the chance that you will crash
and suffer serious injury. Only use Saturn
specic wheel and tire systems developed for
your vehicle, and have them properly installed
by a Saturn certied technician.
SeeBuying New Tires on page 5-62andAccessories
and Modications on page 5-3for additional information.
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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 5-71for more
information.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You cannot know how it has been
used or how far it has been driven. It could fail
suddenly and cause a crash. If you have to
replace a wheel, use a new Saturn original
equipment wheel.
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