2004 SATURN ION fuel cap

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
.............................................. 1-8
Child Restraints
.......................................1-29
Air Bag Systems
......................................1-50
Restraint System Check
............................1-59
Features and Controls..................................... 2-1
Keys
........................................................ 2-3
Doors and Locks
....................................... 2-9
Windows
.................................................2-14
Theft-Deterrent Systems
............................2-17
Starting and Operating Your Vehicle
...........2-18
Mirrors
....................................................2-36
OnStar
®System
......................................2-43
Storage Areas
.........................................2-44
Sunroof
..................................................2-45
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-20
Warning Lights, Gages, and Indicators
........3-27
Message Center
.......................................3-41
Audio System(s)
.......................................3-46Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-31
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-10
Headlamp Aiming
.....................................5-47
Bulb Replacement
....................................5-48
Windshield Wiper Blade Replacement
.........5-57
Tires
......................................................5-58
Appearance Care
.....................................5-87
Vehicle Identication
.................................5-94
Electrical System
......................................5-95
Capacities and Specications
...................5-102
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
............................ 7-9
Index................................................................ 1
2004 Saturn ION Owner ManualM
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If the Light Is Flashing
The following may prevent more serious damage to
your vehicle:
Reducing vehicle speed.
Avoiding hard accelerations.
Avoiding steep uphill grades.
If you are towing a trailer, reduce the amount of
cargo being hauled as soon as it is possible.
If the light stops ashing and remains on steady,
see “If the Light Is On Steady” following.
If the light continues to ash, when it is safe to do so,
stop the vehicle.Find a safe place to park your vehicle.
Turn the key off, wait at least 10 seconds and restart
the engine. If the light remains on steady, see “If the
Light Is On Steady” following. If the light is still ashing,
follow the previous steps, and see your retailer for
service as soon as possible.
If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully
install the cap. SeeFilling Your Tank on page 5-8.
The diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
3-37
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Here are four things that some owners ask about.
None of these show a problem with your fuel gage:
At the service station, the fuel pump shuts off before
the gage reads full.
It takes a little more or less fuel to ll up than the
gage indicated. For example, the gage may have
indicated the tank was half full, but it actually took a
little more or less than half the tank’s capacity to
ll the tank.
The gage moves a little when you turn a corner or
speed up.
The gage takes a few seconds to stabilize after the
ignition is turned on, and will go back to empty
when you turn the ignition off.
For your fuel tank capacity, seeCapacities and
Specications on page 5-102.
Message Center
The message center is located in the instrument panel
cluster. It gives you important safety and maintenance
facts.
If there are several messages, each message will be
shown for a few seconds and will continue to repeat until
cleared. To clear a message, press the trip/reset
button while the message you want to clear is being
displayed.
Many messages will also cause a chime to sound,
to alert you to the message.
Changing the Language (Canada Only)
Vehicles rst sold in Canada have instrument panel
clusters that show messages in either English or French.
To change the language, do the following:
1. Turn the ignition on.
2. Press the trip/reset button until the current language
of ENGLISH or FRENCH is displayed.
3. Press and hold the trip/reset button for several
seconds until the language is changed.
4. Press the trip/reset button to return to the odometer
display.
3-41
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Loading Your Vehicle
Item Description Total
AVehicle Capacity Weight
for Example 3 =1,000 lbs (453 kg)
BSubtract Occupant Weight
200 lbs (91 kg)×5=1,000 lbs (453 kg)
CAvailable Occupant and
Cargo Weight =0 lbs (0 kg)
Refer to your vehicle’s tire and loading information label
for specic information about your vehicle’s capacity
weight and seating positions. The combined weight of the
driver, passengers and cargo should never exceed your
vehicle’s capacity weight. Also seeTowing a Trailer on
page 4-39.
Certication Label
The Certication label is found on the rear edge of the
driver’s door. It tells you the gross weight capacity
of your vehicle, called the Gross Vehicle Weight Rating
(GVWR). The GVWR includes the weight of the
vehicle, all occupants, fuel and cargo. Never exceed the
GVWR for your vehicle or the Gross Axle Weight
Rating (GAWR) for either the front or rear axle. Example 3
4-37
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Towing a Trailer
{CAUTION:
If you do not use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well — or even
at all. You and your passengers could be
seriously injured. You may also damage your
vehicle; the resulting repairs would not be
covered by your warranty. Pull a trailer only if
you have followed all the steps in this section.
Ask your dealer for advice and information
about towing a trailer with your vehicle.
Notice:Pulling a trailer improperly can damage
your vehicle and result in costly repairs not covered
by your warranty. To pull a trailer correctly, follow
the advice in this part and see your retailer for
important information about towing a trailer with
your vehicle.Your vehicle can tow a trailer if it is equipped with the
proper trailer towing equipment. To identify what
the vehicle trailering capacity is for your vehicle, you
should read the information in “Weight of the Trailer” that
appears later in this section. But trailering is different
than just driving your vehicle by itself. Trailering means
changes in handling, durability and fuel economy.
Successful, safe trailering takes correct equipment, and
it has to be used properly.
That’s the reason for this part. In it are many time-tested,
important trailering tips and safety rules. Many of
these are important for your safety and that of your
passengers. So please read this section carefully before
you pull a trailer.
Load-pulling components such as the engine,
transmission, rear axle, wheel assemblies and tires are
forced to work harder against the drag of the added
weight. The engine is required to operate at relatively
higher speeds and under greater loads, generating extra
heat. What’s more, the trailer adds considerably to
wind resistance, increasing the pulling requirements.
4-39
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Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-4
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-5
California Fuel...............................................5-6
Additives.......................................................5-6
Fuels in Foreign Countries...............................5-7
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.......................5-9
Checking Things Under the Hood....................5-10
Hood Release..............................................5-10
Engine Compartment Overview.......................5-12
Engine Oil...................................................5-15
Engine Air Cleaner/Filter................................5-22
Automatic Transaxle Fluid..............................5-24
Manual Transaxle Fluid..................................5-25
Hydraulic Clutch...........................................5-25
Engine Coolant.............................................5-26Coolant Surge Tank Pressure Cap..................5-29
Engine Overheating.......................................5-29
Cooling System............................................5-32
Windshield Washer Fluid................................5-37
Brakes........................................................5-38
Battery........................................................5-41
Jump Starting...............................................5-42
Headlamp Aiming...........................................5-47
Bulb Replacement..........................................5-48
Halogen Bulbs..............................................5-48
Headlamps (Sedan)......................................5-48
Headlamps (Coupe)......................................5-50
Front Turn Signal Lamps (Sedan)...................5-51
Front Turn Signal and Parking Lamps
(Coupe)...................................................5-53
Fog Lamps..................................................5-53
Sidemarker Lamps (Coupe)............................5-54
Center High-Mounted Stoplamp (CHMSL).........5-55
Taillamps, Stoplamps and Back-up Lamps........5-55
Replacement Bulbs.......................................5-56
Section 5 Service and Appearance Care
5-1
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Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions
on the pump island. Turn off your engine when
CAUTION: (Continued)
CAUTION: (Continued)
you are refueling. Do not smoke if you are near
fuel or refueling your vehicle. Keep sparks,
ames and smoking materials away from fuel.
Do not leave the fuel pump unattended when
refueling your vehicle — this is against the law
in some places. Keep children away from the
fuel pump; never let children pump fuel.
The fuel ller cap is located behind a hinged door on
the passenger’s side of your vehicle. It is tethered to the
door to prevent loss while refueling. Make sure that
water, snow, and dirt are kept away from the ller cap
and ller pipe nozzle.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). It will require about 1/2 of a turn
to remove the cap. The fuel cap has a spring in it; if you
let go of the cap too soon, it will spring back to the
right (clockwise).
5-8
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{CAUTION:
If you get fuel on yourself and then something
ignites it, you could be badly burned. Fuel can
spray out on you if you open the fuel cap too
quickly. This spray can happen if your tank is
nearly full, and is more likely in hot weather.
Open the fuel cap slowly and wait for any “hiss”
noise to stop. Then unscrew the cap all the way.
Be careful not to spill fuel. Clean fuel from painted
surfaces as soon as possible. SeeCleaning the Outside
of Your Vehicle on page 5-90.
When you put the fuel cap back on, turn it to the right
(clockwise) about 1/4 of a turn until you hear three
clicks. Make sure you fully install the cap. The diagnostic
system can determine if the fuel cap has been left off
or improperly installed. This would allow fuel to
evaporate into the atmosphere and may cause the
malfunction indicator lamp to come on. SeeMalfunction
Indicator Lamp on page 3-36.
Notice:If you need a new fuel cap, be sure to get the
right type. Your dealer can get one for you. If you get
the wrong type, it may not t properly. This may cause
your malfunction indicator lamp to light and may
damage your fuel tank and emissions system.
SeeMalfunction Indicator Lamp on page 3-36.
Filling a Portable Fuel Container
{CAUTION:
Never ll a portable fuel container while it is in
your vehicle. Static electricity discharge from
the container can ignite the gasoline vapor.
You can be badly burned and your vehicle
damaged if this occurs. To help avoid injury to
you and others:
Dispense gasoline only into approved
containers.
Do not ll a container while it is inside a
vehicle, in a vehicle’s trunk, pickup bed or
on any surface other than the ground.
Bring the ll nozzle in contact with the
inside of the ll opening before operating
the nozzle. Contact should be maintained
until the lling is complete.
Do not smoke while pumping gasoline.
5-9
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