2006 SATURN RELAY engine

Fuses Usage
1 Right High Beam
2 Fuel Pump
3 Diode
SPARE Spare
SPARE Spare
4 Left High Beam
SPARE Spare
SPARE Spare
SPARE Spare
5 Not Used
6 Air Conditioning Clutch
7 Horn
8 Left Low Beam
9Powertrain Control Module,
Electronic Throttle Control
10 Not Used
11 Transmission Solenoid
12 Right Low BeamFuses Usage
13 Anti-lock Brake System
14 Powertrain Control Module Ignition
15 Electronic Ignition
16 Fuel Injector
17Climate Control, RPA, Cruise
Control
18 Electronic Throttle Control
19 Engine Sensor, Evaporator
20 Airbag
21 Not Used
22 Emission, All-Wheel Drive
23 Auxiliary Power
24 Front Windshield Washer
25 AC/DC Inverter
26 Rear Blower
27 Front Blower
28 Front Windshield Wiper
5-101
ProCarManuals.com

Capacities and Specications
The following approximate capacities are given in English and metric measurements. SeeRecommended Fluids and
Lubricants on page 6-11for more information.
ApplicationCapacities
English Metric
Automatic Transaxle — Pan Removal and Replacement 7.4 qt 7.0 L
AWD Automatic Transaxle — Pan Removal and Replacement 8.7 qt 8.3 L
Cooling System
Front A/C 11.3 qt 10.7 L
Front and Rear A/C 12.8 qt 12.2 L
Engine Oil with Filter 4.0 qt 3.8 L
Fuel Capacity 25.1 gal 95.0 L
Wheel Nut Torque 100 ft-lb 140Y
All capacities are approximate. When adding, be sure to ll to the approximate level, as recommended in this
manual. Recheck uid level after lling.
Engine VIN Code Transaxle Spark Plug Gap
3.5L V6 L Automatic 0.060 inches (1.5 mm)
3.9L V6 1 Automatic 0.040 inches (1.1 mm)
5-103
ProCarManuals.com

Maintenance Schedule
Introduction
Important: Keep engine oil at the proper level and
change as recommended.
Maintenance Requirements
Notice:Maintenance intervals, checks, inspections,
replacement parts, and recommended uids and
lubricants as prescribed in this manual are
necessary to keep your vehicle in good working
condition. Any damage caused by failure to follow
scheduled maintenance may not be covered by
warranty.
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance is
important. Improper vehicle maintenance can even
affect the quality of the air we breathe. Improper uid
levels or the wrong tire ination can increase the level of
emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good condition,
be sure to maintain your vehicle properly.
Using the Maintenance Schedule
We at Saturn want to help you keep your vehicle in good
working condition. But we do not know exactly how
you will drive it. You may drive very short distances only
a few times a week. Or you may drive long distances
all the time in very hot, dusty weather. You may
use your vehicle in making deliveries. Or you may drive
it to work, to do errands, or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read
the following and note how you drive. If you have any
questions on how to keep your vehicle in good condition,
see your Saturn retailer.
This schedule is for vehicles that:
carry passengers and cargo within recommended
limits. You will nd these limits on the tire and
loading information label. SeeLoading Your Vehicle
on page 4-33.
are driven on reasonable road surfaces within legal
driving limits.
use the recommended fuel. SeeGasoline Octane
on page 5-4.
6-2
ProCarManuals.com

Scheduled Maintenance
When the CHANGE OIL SOON message comes on,
it means that service is required for your vehicle. Have
your vehicle serviced as soon as possible within the
next 600 miles (1 000 km). It is possible that, if you
are driving under the best conditions, the engine oil
life system may not indicate that vehicle service
is necessary for over a year. However, your engine oil
and lter must be changed at least once a year and
at this time the system must be reset. Your Saturn
retailer has Saturn-trained service technicians who will
perform this work using genuine Saturn parts and
reset the system.
If the engine oil life system is ever reset accidentally,
you must service your vehicle within 3,000 miles
(5 000 km) since your last service. Remember to reset
the oil life system whenever the oil is changed. See
Engine Oil Life System on page 5-18for information on
the Engine Oil Life System and resetting the system.When the CHANGE OIL SOON message appears,
certain services, checks, and inspections are required.
Required services are described in the following for
“MaintenanceI” and “MaintenanceII.” Generally,
it is recommended that your rst service be
MaintenanceI, your second service be MaintenanceII,
and that you alternate MaintenanceIand MaintenanceII
thereafter. However, in some cases, MaintenanceII
may be required more often.
MaintenanceI— Use MaintenanceIif the CHANGE
OIL SOON message comes on within 10 months
since the vehicle was purchased or MaintenanceIIwas
performed.
MaintenanceII— Use MaintenanceIIif the previous
service performed was MaintenanceI. Always use
MaintenanceIIwhenever the message comes on
10 months or more since the last service or if the
message has not come on at all for one year.
6-4
ProCarManuals.com

Scheduled Maintenance
Service MaintenanceIMaintenanceII
Change engine oil and lter. SeeEngine Oil on page 5-15. Reset oil life system.
SeeEngine Oil Life System on page 5-18.An Emission Control Service.••
Lubricate chassis components.See footnote #.••
Visually check for any leaks or damage.See footnote (k).••
Inspect engine air cleaner lter. If necessary, replace lter. SeeEngine Air
Cleaner/Filter on page 5-20.See footnote (g).•
Rotate tires and check ination pressures and wear. SeeTire Inspection and
Rotation on page 5-60and “Tire Wear Inspection” inAt Least Once a Month
on page 6-9.••
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).•
Check transaxle uid level and add uid as needed.•
Replace passenger compartment air lter.See footnote (l).•
Inspect throttle system.See footnote (j).•
6-5
ProCarManuals.com

Additional Required Services
The following services should be performed at the rst maintenance service (IorII) after the indicated miles (kilometers)
shown for each item.
Additional Required Services
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)
Inspect fuel system for damage
or leaks.• •••••
Inspect exhaust system for loose or
damaged components.• •••••
Replace engine air cleaner lter. See
Engine Air Cleaner/Filter on page 5-20.•••
Change automatic transaxle uid and
lter (severe service).See footnote (h).•••
Change automatic transaxle uid and
lter (normal service).•
Replace spark plugs and inspect spark
plug wires.An Emission Control
Service.•
Engine cooling system service (or every
ve years, whichever occurs rst).
An Emission Control Service. See
footnote (i).•
Inspect engine accessory drive belt.
An Emission Control Service. See
footnote (m).•
6-6
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 5-23 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.
(l)If you drive regularly under dusty conditions, the lter
may require replacement more often.
(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 6-11.
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 5-15for 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