2004 SATURN ION brakes
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A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-22.
B. Engine Oil Fill Location. SeeEngine Oil on
page 5-15.
C. Engine Oil Dipstick Location. SeeEngine Oil on
page 5-15.
D. Brake Master Cylinder. SeeBrakes on page 5-38
andHydraulic Clutch on page 5-25.
E. Remote Positive Terminal Location. SeeJump
Starting on page 5-42.F. Engine Compartment Fuse Block. SeeFuses and
Circuit Breakers on page 5-95.
G. Surge Tank. SeeEngine Coolant on page 5-26.
H. Windshield Washer Fluid Reservoir. SeeWindshield
Washer Fluid on page 5-37.
Before closing the hood, be sure all ller caps are on
properly.
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Page 245 of 380
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.
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Page 255 of 380
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.
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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.
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Checking Brake Fluid
You can check the brake uid level without removing
the reservoir cap by just looking at the brake uid
reservoir. The uid level should be at or below the MAX
ll mark. After work has been done on the brake
hydraulic system, make sure the level does not exceed
the MAX ll mark on the reservoir.
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 6-14. Be sure to 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.
SeeAppearance Care on page 5-87.
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Brake Wear
Your vehicle has front disc brakes and rear drum 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 speci cations.
The rear drum brakes do not have wear indicators,
but if you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. Also, the
rear brake drums should be removed and inspected
each time the tires are removed for rotation or changing.
When you have the front brake pads replaced, have
the rear brakes inspected, too.
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 make a moderate brake stop, your brakes
adjust for wear. If you rarely make a moderate or heavier
stop, then your brakes might not adjust correctly. If you
drive in that way, then — very carefully — make a few
moderate brake stops about every 1,000 miles
(1 600 km), so your brakes will adjust properly.
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Page 271 of 380
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 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.
Battery
Your new vehicle comes with a maintenance free
ACDelco®battery. When it is time for a new battery,
get one that has the replacement number shown on the
original battery’s label. We recommend an ACDelco
®
battery.
Your vehicle’s battery is located in the trunk next to the
compact spare tire. To access the battery, use the
trunk’s oor carpet latch to lift the cover up.Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you are not going to drive your vehicle for 25 days
or more, remove the black, negative (−) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
are not careful. SeeJump Starting on page 5-42
for tips on working around a battery without
getting hurt.
Contact your Saturn retailer to learn how to prepare
your vehicle for longer storage periods.
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Tire Terminology and De nitions
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.
Belt:A rubber coated layer of cords that is located
between the plies and the tread. Cords may be made
from steel or other reinforcing materials.
Bead:The tire bead contains steel wires wrapped by
steel cords that hold the tire onto the rim.
Bias Ply Tire:A pneumatic tire in which the plies are
laid at alternate angles less than 90 degrees to the
centerline of the tread.Cold In ation Pressure:The amount of air pressure
in a tire, measured in pounds per square inch (psi) before
a tire has built up heat from driving. SeeIn ation - Tire
Pressure on page 5-66.
Curb Weight:This means the weight of a motor
vehicle with standard and optional equipment including
the maximum capacity of fuel, oil and coolant, but
without passengers and cargo.
DOT Markings:A code molded into the sidewall of a
tire signifying that the tire is in compliance with the
U.S. Department of Transportation motor vehicle safety
standards. The DOT code includes the Tire Identi cation
Number (TIN), an alphanumeric designator which can
also identify the tire manufacturer, production plant,
brand and date of production.
GVWR:Gross Vehicle Weight Rating, seeLoading
Your Vehicle on page 4-33.
GAWR FRT:Gross Axle Weight Rating for the front
axle, seeLoading Your Vehicle on page 4-33.
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