2004 SATURN ION clutch

A. Engine Oil Dipstick Location. SeeEngine Oil on
page 5-15.
B. Electric Cooling Fan. SeeCooling System on
page 5-32.
C. Engine Oil Fill Location. SeeEngine Oil on
page 5-15.
D. Radiator Pressure Cap. SeeEngine Coolant on
page 5-26.
E. Brake Master Cylinder. SeeBrakes on page 5-38
andHydraulic Clutch on page 5-25.
F. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
G. Engine Compartment Fuse Block. SeeFuses and
Circuit Breakers on page 5-95.
H. Remote Positive Terminal Location. SeeJump
Starting on page 5-42.
I. Surge Tank. SeeCoolant Surge Tank Pressure Cap
on page 5-29.
J. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-37.
Before closing the hood, be sure all ller caps are on
properly.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.
Turn off the engine and give the oil several minutes to
drain back into the oil pan. If you don’t, the oil
dipstick might not show the actual level.
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.
5-15
ProCarManuals.com

If you do not use your vehicle under any of these
conditions, the uid and lter do not require changing.
Notice:For VTi variable transaxles, use only Saturn
Variable Transaxle Fluid. Using any other uid will
result in transaxle damage. Damage cause by
the use of uid other than Saturn Variable Transaxle
Fluid will not be covered by your warranty.
Notice:For ve-speed automatic transaxles,
use only Saturn T-IV Transaxle Fluid. Using any
other uid will result in transaxle damage. Damage
cause by the use of uid other than Saturn T-IV
Transaxle Fluid will not be covered by your
warranty.Manual Transaxle Fluid
It is not necessary to check the transaxle uid level.
A transaxle uid leak is the only reason for uid loss.
If a leak occurs, take the vehicle to your retailer’s service
department and have it repaired as soon as possible.
You may also have your uid level checked by your
retailer or service center when you have your oil
changed. SeeRecommended Fluids and Lubricants
on page 6-14for the proper uid to use.
Hydraulic Clutch
The hydraulic clutch linkage in your vehicle is
self-adjusting. This system does not have its own
reservoir. It receives uid from the brake master
cylinder reservoir.
SeeBrakes on page 5-38for more information.
5-25
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Brakes
Brake Fluid
Your brake master cylinder reservoir is lled with DOT-3
brake uid. SeeEngine 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 or hydraulicclutch system if you have a manual transaxle. If it is,
you should have both systems checked and the
necessary repairs made, since a leak means that sooner
or later your brakes and/or clutch will not work well, or
will not work at all.
So, it isn noa 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 and/or clutch 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 3-32.
5-38
ProCarManuals.com

Instrument Panel Fuse Block
Some fuses are in a fuse block on the driver’s side of
the vehicle, near the driver’s right leg. Loosen the screw
on the cover and remove the cover.
Fuses Usage
AIR BAGAir bags, Sensing and Diagnostic
Module (SDM)
ACCOMMO-
DATION
INTERFACE/
ONSTAREntertainment, Mobile
Communications, OnStar
CRUISECruise Control Module, Clutch Start
Switch
EPS/CRUISE Cruise Control Switches, EPS Unit
5-96
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Engine Compartment Fuse Block
(2.2L L4 Engine)
Some fuses are in a fuse block in the engine
compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Fuses Usage
1 ECM/TCMEngine Control Module,
Transmission Control Module
4 HDLP-RH Passenger’s Side Headlamp
5 A/C Air Conditioning Clutch Relay
8 ABS2Anti-Lock Brake System,
Traction Control Module
9 ECM Engine Control Module
10 ERLSCanister Purge Solenoid, Canister
Vent Solenoid, Low Coolant
Switch, Oxygen Sensors
11 IGNElectric Ignition Control Module,
Charging System, Neutral Stop
Back-Up Switch
13 TRANS2 Transaxle (VTi Variable)
14 TRANS1Transmission Control Module,
Neutral Stop Back-Up
15 BACK-UP PRNDIL, Back-up Switch
16 INJECTORS Fuel Injectors (Cylinder 1, 2, 3, 4)
17 FOG Fog Lamp Micro Relay
5-98
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Fuses Usage
18 HDLP-LH Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 PREM AUDIOEntertainment, Premium Radio
Amplier
22 ABSAnti-Lock Brake System,
Traction Control Module
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABSAnti-Lock Brake System,
Traction Control Module
41 IP BATT2 Body Control Module
42 EPS2 Electric Power Steering
43 EPS1 Electric Power Steering
45 COOLING
FANCooling Fan Mini Relay
46 CRANKPowertrain Control Module
Mini RelayFuses Usage
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control Module
Relays Usage
24 A/C Air Conditioning Clutch
25 HORN Horn
26 FOG LAMP Fog Lamps
28 RUN/CRANK Body Control Module
30 COOLING
FANEngine Cooling Fan
31 PCM CONT ECM
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
5-99
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Engine Compartment Fuse Block
(2.0L Supercharged Engine)
Some fuses are in a fuse block in the engine
compartment on the driver’s side of the vehicle.
SeeEngine Compartment Overview on page 5-12for
more information on location.
Fuses Usage
1 ECM Engine Control Module
4 RH HDLP Passenger’s Side Headlamp
5 A/C Air Conditioning Clutch Relay
8 ABS Anti-Lock Brake System
9 ECM/ETC Engine Control Module
10 EMISSCanister Purge Solenoid, Mass Air
Flow Sensor, Low Coolant Switch,
Oxygen Sensors
11 IGN Ignition Coils (1,2,3,4)
13 ECM Engine Control Module
14 BOOST Engine Boost Solenoid
15 BACK-UP Back-up Switch
16 INJECTORS Fuel Injectors (Cylinder 1, 2, 3, 4)
18 LH HDLP Driver’s Side Headlamp
19 WIPER Wiper Mini Relay
20 HORN Horn Micro Relay
21 RADIO Radio
5-100
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Fuses Usage
22 ABS Anti-Lock Brake System
23 RR DEFOG Rear Defog Mini Relay
38 RUN/CRANK Ignition 1 Mini Relay
39 IP BATT1 Body Control Module
40 ABS Anti-Lock Brake System
41 IP BATT2 Body Control Module
43 EPS Electric Power Steering
44 COOLING
FAN 2Cooling Fan Mini Relay
45 COOLING
FAN 1Cooling Fan Mini Relay
46 CRANK Crank
47 IP BATT 1A Body Control Module
48 RUN (IGN 3) Body Control ModuleRelays Usage
24 A/C CLUTCH Air Conditioning Clutch
25 HORN Horn
27 AFTER
COOLER PUMPAfter Cooler Pump
28 RUN/CRANK Body Control Module
29 POWERTRAINPowertrain
30 COOLING
FAN 1Engine Cooling Fan
31 ECM CONT Starter Solenoid
32 WIPER1 Wiper System
33 WIPER2 Wiper System
34 REAR DEFOG Rear Window Defroster
Diodes Usage
35 A/C Air Conditioning Diode
37 WIPER Wiper Diode
5-101
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