brake SATURN RELAY 2006 Repair Manual

Tire Chains
{CAUTION:
Do not use tire chains. There is not enough
clearance. Tire chains used on a vehicle
without the proper amount of clearance can
cause damage to the brakes, suspension or
other vehicle parts. The area damaged by the
tire chains could cause you to lose control of
your vehicle and you or others may be injured
in a crash.
CAUTION: (Continued)
CAUTION: (Continued)
Use another type of traction device only if its
manufacturer recommends it for use on your
vehicle and tire size combination and road
conditions. Follow that manufacturer’s
instructions. To help avoid damage to your
vehicle, drive slowly, readjust or remove the
device if it is contacting your vehicle, and do
not spin your vehicle’s wheels. If you do nd
traction devices that will t, install them on the
front tires.
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If a Tire Goes Flat
It is unusual for a tire to blowout while you are driving,
especially if you maintain your vehicle’s tires properly.
If air goes out of a tire, it is much more likely to leak out
slowly. But if you should ever have a blowout, here
are a few tips about what to expect and what to do:
If a front tire fails, the at tire will create a drag that pulls
the vehicle toward that side. Take your foot off the
accelerator pedal and grip the steering wheel rmly.
Steer to maintain lane position, and then gently brake to
a stop well out of the traffic lane.
A rear blowout, particularly on a curve, acts much like a
skid and may require the same correction you would
use in a skid. In any rear blowout remove your foot from
the accelerator pedal. Get the vehicle under control
by steering the way you want the vehicle to go. It may
be very bumpy and noisy, but you can still steer. Gently
brake to a stop, well off the road if possible.{CAUTION:
Lifting a vehicle and getting under it to do
maintenance or repairs is dangerous without
the appropriate safety equipment and training.
The jack provided with your vehicle is
designed only for changing a at tire. If it is
used for anything else, you or others could be
badly injured or killed if the vehicle slips off
the jack. Use the jack provided with your
vehicle only for changing a at tire.
If a tire goes at, the next part shows how to use the
jacking equipment to change a at tire safely.
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Changing a Flat Tire
If a tire goes at, avoid further tire and wheel damage
by driving slowly to a level place. Turn on your vehicle’s
hazard warning ashers. SeeHazard Warning Flashers
on page 3-6for more information.
{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).
CAUTION: (Continued)
CAUTION: (Continued)
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.
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9. Lower the vehicle by attaching the folding wheel
wrench to the jack and turning the wrench
counterclockwise. Lower the jack completely.
{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 5-103for 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 5-103for the wheel nut
torque specication.
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Fuses Usage
1 Right High Beam
2 Fuel Pump
3 Diode
SPARE Spare
SPARE Spare
4 Left High Beam
SPARE Spare
SPARE Spare
SPARE Spare
5 Not Used
6 Air Conditioning Clutch
7 Horn
8 Left Low Beam
9Powertrain Control Module,
Electronic Throttle Control
10 Not Used
11 Transmission Solenoid
12 Right Low BeamFuses Usage
13 Anti-lock Brake System
14 Powertrain Control Module Ignition
15 Electronic Ignition
16 Fuel Injector
17Climate Control, RPA, Cruise
Control
18 Electronic Throttle Control
19 Engine Sensor, Evaporator
20 Airbag
21 Not Used
22 Emission, All-Wheel Drive
23 Auxiliary Power
24 Front Windshield Washer
25 AC/DC Inverter
26 Rear Blower
27 Front Blower
28 Front Windshield Wiper
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J-Case Fuses Usage
PLR Fuse Puller
29 Fan 1
30 Starter Solenoid
31 Anti-lock Brake System Motor
32 Blank
33 Fan 2
34 Front Blower High
35 Battery Main 3
36 Rear Defogger
37 Battery Main 2
38 SpareRelays Usage
RUN RLY Starter
LO BEAM Low Beam
FUEL PUMP Fuel Pump
HORN Horn
AC/CLTCH Air Conditioning Clutch
HI BEAM High Beam
PWR/TRN Powertrain
WPR2 Wiper 2
WPR1 Wiper 1
FAN 1 Fan 1
CRNK Crank
IGN MAIN Ignition Main
FAN2 Fan 2
FAN3 Fan 3
BLANK Not Used
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-15. Reset oil life system.
SeeEngine Oil Life System on page 5-18.An Emission Control Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (k).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-20.See footnote (g).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 5-60and “Tire Wear Inspection” inAt Least Once a Month
on page 6-9.••
Inspect brake system.See footnote (a).••
Check engine coolant and windshield washer uid levels and add uid 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).•
Check transaxle uid level and add uid as needed.•
Replace passenger compartment air lter.See footnote (l).•
Inspect throttle system.See footnote (j).•
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Maintenance Footnotes
#Lubricate the suspension, steering linkage, transaxle
shift linkage, and the underbody contact points and
linkage.
(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. Check parking brake adjustment.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose, or missing parts,
signs of wear, or lack of lubrication. 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 wiper blades 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, hood latch
assemblies, secondary latches, pivots, spring anchor
and release pawl, hood and door hinges, rear folding
seats, liftgate hinges, fuel door hinge, power sliding door
cable, and sliding door track(s). 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)If you drive regularly under dusty conditions, inspect
the lter at each engine oil change.
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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 5-23for further details.
Windshield Washer Fluid Level Check
Check the windshield washer uid level in the windshield
washer uid reservoir and add the proper uid if
necessary.
At Least Once a Month
Tire Ination Check
Visually inspect your vehicle’s tires and make sure they
are inated to the correct pressures. Do not forget to
check the spare tire. SeeTires on page 5-53for further
details. Check to make sure the spare tire is stored
securely. SeeChanging a Flat Tire on page 5-71.
Tire Wear Inspection
Tire rotation may be required for high mileage highway
drivers prior to the Engine Oil Life System service
notication. Check the tires for wear and, if necessary,
rotate the tires. SeeTire Inspection and Rotation on
page 5-60.
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 2-39.
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 vehicle
should start only in PARK (P) or NEUTRAL (N).
If the vehicle starts in any other position, contact
your Saturn 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 2-39.
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 Saturn retailer for service.
Ignition Transaxle Lock Check
While parked, and with the parking brake set, try to turn
the ignition to LOCK in each shift lever position.
The ignition should turn to LOCK only when the
shift lever is in PARK (P).
The key should come out only in LOCK.
Contact your Saturn retailer if service is required.
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.
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