2005 SATURN RELAY radiator

How to Add Coolant to the Coolant
Recovery Tank
If you have not found a problem yet, but the coolant
level is not at or above the full cold mark, add a
50/50 mixture of clean, drinkable water and DEX-COOL
®
engine coolant at the coolant recovery tank. See
Engine Coolant on page 5-22for more information.
{CAUTION:
Adding only plain water to your cooling
system can be dangerous. Plain water, or
some other liquid such as alcohol, can boil
before the proper coolant mixture will. Your
vehicle’s coolant warning system is set for the
proper coolant mixture. With plain water or the
wrong mixture, your engine could get too hot
but you would not get the overheat warning.
Your engine could catch re and you or others
could be burned. Use a 50/50 mixture of clean,
drinkable water and DEX-COOL
®coolant.Notice:In cold weather, water can freeze and crack
the engine, radiator, heater core and other parts.
Use the recommended coolant and the proper
coolant mixture.
When the coolant in the coolant recovery tank is at or
above the full cold mark, start your vehicle.
{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
5-30
ProCarManuals.com

If the overheat warning continues, there is one more
thing you can try. You can add the proper coolant
mixture directly to the radiator, but be sure the cooling
system is cool before you do it.
{CAUTION:
Steam and scalding liquids from a hot cooling
system can blow out and burn you badly. They
are under pressure, and if you turn the radiator
pressure cap — even a little — they can come
out at high speed. Never turn the cap when the
cooling system, including the radiator pressure
cap, is hot. Wait for the cooling system and
radiator pressure cap to cool if you ever have
to turn the pressure cap.
How to Add Coolant to the Radiator
Notice:Your engine has a specic radiator
ll procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.1. You can remove the radiator pressure cap when
the cooling system, including the radiator pressure
cap and upper radiator hose, is no longer hot.
Turn the pressure cap slowly counterclockwise until
it rst stops. Do not press down while turning the
pressure cap.
If you hear a hiss, wait for that to stop. A hiss
means there is still some pressure left.
2. Then keep turning the pressure cap, but now push
down as you turn it. Remove the pressure cap.
5-31
ProCarManuals.com

{CAUTION:
You can be burned if you spill coolant on hot
engine parts. Coolant contains ethylene glycol
and it will burn if the engine parts are hot
enough. Do not spill coolant on a hot engine.
3. After the engine cools, open the coolant air bleed
valves.
There are two bleed valves. One is located on the
thermostat housing. The other is located on the
thermostat bypass tube.4. Fill the radiator with the proper DEX-COOL
®
coolant mixture, up to the base of the ller
neck. SeeEngine Coolant on page 5-22for more
information about the proper coolant mixture.
If you see a stream of coolant coming from an air
bleed valve, close the valve. Otherwise, close
the valves after the radiator is lled.
5. Rinse or wipe any spilled coolant from the engine
and the compartment. Housing
Bypass Tube
5-32
ProCarManuals.com

6. Start the engine and let it run until you can feel the
upper radiator hose getting hot. Watch out for the
engine cooling fans.
7. By this time, the coolant level inside the radiator
ller neck may be lower. If the level is lower, add
more of the proper DEX-COOL
®coolant mixture
through the ller neck until the level reaches
the base of the ller neck.
8. Then replace the pressure cap. At any time during
this procedure if coolant begins to ow out of the ller
neck, reinstall the pressure cap. Be sure the arrows
on the pressure cap line up with the vent tube.9. Then ll the coolant recovery tank to the full
cold mark.
10. Put the cap back on the coolant recovery tank.
5-33
ProCarManuals.com

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.
6-7
ProCarManuals.com

(h)Change automatic 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 5-22 for what to use. Inspect hoses.
Clean radiator, condenser, pressure cap, and ller neck.
Pressure test the cooling system and pressure cap.
(j)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.
(k)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.
(m)Visually inspect belt for fraying, excessive cracks, or
obvious damage. Replace belt if necessary.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 6-12.
At Each Fuel Fill
It is important to perform these underhood checks at
each fuel ll.
Engine Oil Level Check
Check the engine oil level and add the proper oil if
necessary. SeeEngine Oil on page 5-13for further
details.
Notice:It is important to check your oil regularly
and keep it at the proper level. Failure to keep your
engine oil at the proper level can cause damage
to your engine not covered by your warranty.
6-8
ProCarManuals.com

Q
Questions and Answers About Safety Belts.........1-26
R
Radiator Pressure Cap....................................5-25
Radios..........................................................3-72
Care of Your CD and DVD Player................3-111
Care of Your CDs and DVDs.......................3-111
Radio with CD............................................3-73
Rear Seat Audio........................................3-106
Setting the Time..........................................3-72
Theft-Deterrent..........................................3-109
Understanding Reception............................3-110
Rear Climate Control System............................3-27
Rear Reading Lamps......................................3-18
Rear Safety Belt Comfort Guides......................1-39
Rear Seat Audio (RSA)..................................3-106
Rear Seat Entertainment System.......................3-91
Rear Seat Operation......................................... 1-6
Rear Seat Passengers, Safety Belts..................1-36
Rearview Mirrors.............................................2-41Reclining Seatbacks.......................................... 1-4
Recommended Fluids and Lubricants.................6-12
Recreational Vehicle Towing.............................4-36
Remote Keyless Entry System............................ 2-4
Remote Keyless Entry System, Operation............ 2-5
Removing the Flat Tire and Installing
the Spare Tire.............................................5-73
Removing the Spare Tire and Tools...................5-70
Replacement Bulbs.........................................5-50
Reporting Safety Defects
Canadian Government................................... 7-8
Saturn......................................................... 7-8
United States Government.............................. 7-8
Restraint System Check
Checking the Restraint Systems....................1-79
Replacing Restraint System Parts
After a Crash..........................................1-80
Retained Accessory Power (RAP)......................2-31
Right Front Passenger Position, Safety Belts......1-36
Roadside
Assistance Program....................................... 7-5
Rocking Your Vehicle to Get it Out....................4-30
Running the Engine While Parked.....................2-40
10
ProCarManuals.com