2004 SATURN ION cooling

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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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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Capacities and Specications
The following approximate capacities are given in English and metric conversions. SeeRecommended Fluids and
Lubricants on page 6-14for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a
Use Refrigerant Oil, R134a Systems0.9 lbs. 0.41 kg
Cooling System 6.9 quarts 6.5 L
Engine Oil with Filter
2.2L L4
2.0L Supercharged4.0 quarts
6.75 quarts4.8 L
6.4 L
Fuel Tank 13.5 gallons 50.5 L
Transaxle
Manual
Five-Speed Automatic
VTi Variable1.8 quarts
4.2 quarts
6.9 quarts1.7 L
4.0 L
6.5 L
Wheel Nut Torque 92 lb ft 125Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual. Recheck uid level after lling.
5-102
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Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. Reset oil life system. SeeEngine Oil on
page 5-15.An Emission Control Service.••
Visually check for any leaks or damage.See footnote (j).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-22.An Emission Control Service. See footnote †.••
Rotate tires and check ination pressures and wear. SeeTires on page 5-58.••
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).•
Replace passenger compartment air lter.See footnote (k).•
Inspect throttle system.See footnote (g).•
6-5
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Additional Required Services (cont’d)
Service and Miles (Kilometers)25,000
(41 500)50,000
(83 000)75,000
(125 000)100,000
(166 000)125,000
(207 500)150,000
(240 000)
Replace spark plugs.An Emission
Control Service.•
Replace engine fuel lter.An Emission
Control Service. See footnote †.•
Engine cooling system service (or
every 5 years, whichever occurs rst).
An Emission Control Service. See
footnote (i).•
Inspect engine accessory drive belt.
An Emission Control Service.••••••
Red Line only: Replace engine
accessory drive belt.An Emission
Control Service.•••
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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 drum brake linings for wear or cracks.
Inspect other brake parts, including drums, wheel
cylinders, calipers, parking brake, etc.
(b)Visually inspect front and rear suspension and
steering system for damaged, loose or missing parts or
signs of wear.
(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 air bag
coverings, and have them repaired or replaced. (The air
bag 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.
6-8
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(h)Change automatic transaxle or VTi variable transaxle
uid and lter if the vehicle is mainly driven under one
or more of these conditions:
In heavy city traffic where the outside temperature
regularly reaches 90°F (32°C) or higher.
In hilly or mountainous terrain.
When doing frequent trailer towing.
Uses such as found in taxi, police or delivery
service.
(i)Drain, ush and rell cooling system. See Engine
Coolant on page 5-26for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap and ller neck.
Pressure test the cooling system and pressure cap.
(j)A uid loss in any vehicle system could indicate a
problem. Have the system inspected and repaired and
the uid level checked. Add uid if needed.
(k)Or every 12 months, whichever occurs rst. If you
drive regularly under dusty conditions, the lter may
require replacement more often.Owner Checks and Services
These owner checks and services should be performed
at the intervals specied to help ensure the safety,
dependability and emission control performance of your
vehicle. Your Saturn retailer can assist you with these
checks and services.
Be sure any necessary repairs are completed at once.
Whenever any uids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
inRecommended Fluids and Lubricants on page 6-14.
6-9
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Convenience Net............................................2-45
Coolant
Engine Temperature Gage............................3-35
Heater, Engine............................................2-22
Low Level Warning Message.........................3-43
Surge Tank Pressure Cap.............................5-29
Cooling System..............................................5-32
Cruise Control................................................3-12
Cruise Control Message...................................3-42
Cupholder(s)..................................................2-44
Customer Assistance Information
Customer Assistance for Text
Telephone (TTY) Users............................... 7-4
Customer Satisfaction Procedure..................... 7-2
GM Mobility Program for Persons with
Disabilities................................................ 7-5
Reporting Safety Defects to Saturn.................. 7-9
Reporting Safety Defects to the
Canadian Government................................ 7-9
Reporting Safety Defects to the
United States Government.......................... 7-9
Roadside Assistance Program......................... 7-5
Service Publications Ordering Information........7-10D
Daytime Running Lamps..................................3-15
Defensive Driving............................................. 4-2
Defogging and Defrosting.........................3-21, 3-23
Delayed Locking.............................................2-10
Dinghy Towing (Five-Speed Automatic
Transaxle and VTi Variable Transaxle)............4-31
Dinghy Towing (Manual Transaxle)....................4-32
Disabling the Theft-Deterrent Feature.................3-70
Doing Your Own Service Work........................... 5-4
Dolly Towing (All Transaxles)............................4-33
Dome Lamp...................................................3-18
Door
Delayed Locking..........................................2-10
Locks.......................................................... 2-9
Power Door Locks.......................................2-10
Programmable Automatic Door Locks.............2-10
Rear Door Security Locks.............................2-11
Rear Doors.................................................2-12
Driver
Position, Safety Belt.....................................1-14
Seat Height Adjuster...................................... 1-3
Driving
At Night.....................................................4-15
City...........................................................4-20
Defensive..................................................... 4-2
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