2006 SATURN ION engine overheat

Checking Intercooler System Coolant
(2.0L L4 Engine Only)
Park your vehicle on a level surface and turn off the
engine. When your engine is cold, the coolant level
should be just visible within the horizontal tube section
of the ll neck. When your engine is warm, the
coolant level could be as high as the FULL HOT line,
or a little higher. The FULL HOT line has an arrow
pointing down at it.Notice:This vehicle has a specic coolant ll
procedure. Failure to follow this procedure could
cause your engine to overheat and be severely
damaged.
Adding Coolant
If you need more coolant, add the proper DEX-COOL®
coolant mixture at the surge tank and/or intercooler ll
neck, but only when the engine is cool. SeeCooling
System on page 5-31for instructions on how to add
coolant to the coolant surge tank and/or intercooler
ll neck.
{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.
When replacing a pressure cap, make sure it is
hand-tight and fully seated.
5-28
ProCarManuals.com

Coolant Surge Tank Pressure Cap
Notice:If the pressure cap is not tightly installed,
coolant loss and possible engine damage may
occur. Be sure the cap is properly and tightly
secured.
If you replace your coolant surge tank pressure cap,
a Saturn cap is required.
Engine Overheating
You will nd a coolant temperature gage and a low
coolant level warning message on your vehicle’s
instrument panel. SeeEngine Coolant Temperature
Gage on page 3-36for more information.
You also have a check gage message and a transaxle
uid hot message. SeeCheck Gage Message on
page 3-45andTransaxle Fluid Hot Message on
page 3-45.
Notice:Driving with either the CHK GAGE message
or the COOLANT message displayed in the message
center and the Engine Coolant Temperature Gage on
your instrument panel in the red zone could cause
your vehicle to overheat. SeeEngine Overheating on
page 5-29. Your vehicle could be damaged and the
damages might not be covered by your warranty.
If Steam Is Coming From Your Engine
{CAUTION:
Steam from an overheated engine can burn
you badly, even if you just open the hood.
Stay away from the engine if you see or hear
steam coming from it. Just turn it off and get
everyone away from the vehicle until it cools
down. Wait until there is no sign of steam or
coolant before you open the hood.
If you keep driving when your engine is
overheated, the liquids in it can catch re.
You or others could be badly burned. Stop
your engine if it overheats, and get out of
the vehicle until the engine is cool.
Notice:If your engine catches re because you
keep driving with no coolant, your vehicle can
be badly damaged. The costly repairs would not
be covered by your warranty.
5-29
ProCarManuals.com

If No Steam Is Coming From
Your Engine
If you get an engine overheat warning with no warning
messages, but see or hear no steam, the problem
may not be too serious. Sometimes the engine can get
a little too hot when you:
Climb a long hill on a hot day.
Stop after high-speed driving.
Idle for long periods in traffic.
Tow a trailer.
If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. If you have an air conditioner and it is on, turn it off.
2. Turn on your heater to full hot at the highest fan
speed and open the windows as necessary.
3. Try to minimize engine load. If you are in a traffic
jam, shift to NEUTRAL (N); otherwise, shift to the
highest gear possible while driving.If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning does not come back on, you can drive
normally.
If the warning continues and you have not stopped, pull
over, stop, and park your vehicle right away.
If there is still no sign of steam, you can idle the engine
for three minutes while you are parked. If you still
have the warning, turn off the engine and get everyone
out of the vehicle until it cools down.
You may decide not to lift the hood but to get service
help right away.
5-30
ProCarManuals.com

The coolant level should be at the cold ll line. If it is
not, you may have a leak at the radiator hoses, heater
hoses, radiator, water pump, or somewhere else in
the cooling system.
{CAUTION:
Heater and radiator hoses, and other engine
parts, can be very hot. Do not touch them.
If you do, you can be burned.
Do not run the engine if there is a leak. If you
run the engine, it could lose all coolant. That
could cause an engine re, and you could be
burned. Get any leak xed before you drive
the vehicle.If there seems to be no leak, with the engine on, check
to see if the electric engine cooling fan is running.
If the engine is overheating, the fan should be running.
If it is not, your vehicle needs service. Turn off the
engine.
Notice:Engine damage from running your engine
without coolant is not covered by your warranty.
Notice:Using coolant other than DEX-COOL®may
cause premature engine, heater core or radiator
corrosion. In addition, the engine coolant may
require changing sooner, at 30,000 miles (50 000 km)
or 24 months, whichever occurs rst. Any repairs
would not be covered by your warranty. Always use
DEX-COOL
®(silicate-free) coolant in your vehicle.
5-32
ProCarManuals.com

How to Add Coolant to the Coolant
Surge Tank
If you have not found a problem yet, check to see if
coolant is visible in the surge tank. If coolant is visible
but the coolant level is not at the cold ll line, add a
50/50 mixture of clean, drinkable water and DEX-COOL
®
coolant at the coolant surge tank, but be sure the
cooling system, including the coolant surge tank
pressure cap, is cool before you do it. SeeEngine
Coolant on page 5-25for more information.
{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 coolant
surge tank pressure cap — even a little — they
can come out at high speed. Never turn the
cap when the cooling system, including the
coolant surge tank pressure cap, is hot. Wait
for the cooling system and coolant surge tank
pressure cap to cool if you ever have to turn
the pressure cap.
{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.
5-33
ProCarManuals.com

How to Add Coolant to the
Intercooler System Fill Neck
(2.0L L4 Supercharged Engine Only)
If you have not found a problem yet, turn the engine off
and allow it to cool down, then check to see if coolant
is visible within the horizontal tube section of the
ll neck. If coolant is not visible, add a 50/50 mixture of
clean, drinkable water and DEX-COOL
®coolant to
the ll neck. Be sure the Intercooler System, including
the Intercooler System pressure cap, is cool before
doing so. SeeEngine Coolant on page 5-25for more
information.
{CAUTION:
Turning the Intercooler System pressure cap
when the engine and intercooler are hot can
allow steam and scalding liquids to blow out
and burn you badly. Never turn the Intercooler
System pressure cap, even a little, when the
engine and intercooler are hot.
{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.
5-36
ProCarManuals.com

E
Electrical System
Add-On Equipment......................................5-99
Engine Compartment Fuse Block.................5-102
Floor Console Fuse Block...........................5-100
Fuses and Circuit Breakers.........................5-100
Power Windows and Other Power Options.......5-100
Windshield Wiper Fuses.............................5-100
Engine
Air Cleaner/Filter.........................................5-22
Battery.......................................................5-42
Change Oil Message...................................3-45
Check and Service Engine Soon Light............3-36
Coolant......................................................5-25
Coolant Temperature Gage...........................3-36
Engine Compartment Overview......................5-12
Exhaust.....................................................2-30
Oil .............................................................5-15
Oil Life System...........................................5-20
Overheating................................................5-29
Reduced Power Light...................................3-41
Starting......................................................2-20
Enhanced Traction System (ETS)........................ 4-9
Entry Lighting.................................................3-16
Error Message................................................3-47
Event Data Recorders (EDR)............................. 7-7
Extender, Safety Belt.......................................1-31
F
Filter
Engine Air Cleaner......................................5-22
Finish Damage...............................................5-96
Fixed Mast Antenna........................................3-72
Flashers, Hazard Warning.................................. 3-6
Flash-to-Pass................................................... 3-8
Flat Tire........................................................5-75
Flat Tire, Changing.........................................5-76
Flat Tire, Storing.............................................5-87
Fluid
Automatic Transaxle.....................................5-24
Manual Transaxle........................................5-24
Windshield Washer......................................5-38
Fog Lamps ....................................................3-15
Folding Rear Seat............................................ 1-9
Folding Seatback, Passenger............................. 1-7
Front Turn Signal, Parking and Daytime
Running Lamps...................................5-52, 5-53
Fuel............................................................... 5-4
Additives...................................................... 5-6
California Fuel.............................................. 5-5
Filling a Portable Fuel Container..................... 5-9
Filling Your Tank........................................... 5-7
Fuels in Foreign Countries.............................. 5-6
Gage .........................................................3-42
Gasoline Octane........................................... 5-5
5
ProCarManuals.com