2007 SATURN ION engine

4. Wipe all dust from inside the housing and
inspect the air cleaner and air inlet tube for
cracks, cuts and deterioration. The air
inlet tube must be replaced if it is damaged.
5. Install the air lter element, hose, hose clamp
and cover.
6. For vehicles that have the 2.2L L4 or 2.4L L4
engine, latch the two clips. For vehicles that
have the 2.0L L4 Supercharged engine,
reinstall the three screws.
{CAUTION:
Operating the engine with the air
cleaner/lter off can cause you or others
to be burned. The air cleaner not only
cleans the air; it helps to stop ames if
the engine backres. If it is not there and
the engine backres, you could be
burned. Do not drive with it off, and be
careful working on the engine with the air
cleaner/lter off.Notice:If the air cleaner/lter is off, a backre
can cause a damaging engine re. And, dirt
can easily get into your engine, which will
damage it. Always have the air cleaner/lter in
place when you are driving.
Automatic 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.
Change the uid and lter at the intervals listed in
Additional Required Services on page 394, and
be sure to use the transaxle uid listed in
Recommended Fluids and Lubricants on page 402.
Notice:Use of the incorrect automatic
transaxle uid may damage your vehicle, and
the damages may not be covered by your
warranty. Always use the automatic transaxle
uid listed inRecommended Fluids and
Lubricants on page 402.
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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. SeeRecommended Fluids
and Lubricants on page 402for 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 308for more information.
Engine Coolant
The cooling system in your vehicle is lled with
DEX-COOL®engine coolant. This coolant is
designed to remain in your vehicle for ve years or
150,000 miles (240 000 km), whichever occurs
rst, if you add only DEX-COOL
®extended
life coolant.The following explains your cooling system and
how to add coolant when it is low. If you have
a problem with engine overheating, seeEngine
Overheating on page 297.
A 50/50 mixture of clean, drinkable water and
DEX-COOL
®coolant will:
Give freezing protection down to
−34°F (−37°C).
Give boiling protection up to 265°F (129°C).
Protect against rust and corrosion.
Help keep the proper engine temperature.
Let the warning lights and gages work as
they should.
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 the
rst maintenance service after each
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.
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What to Use
Use a mixture of one-half clean, drinkable water
and one-half DEX-COOL®coolant which will
not damage aluminum parts. If you use this coolant
mixture, you do not need to add anything else.
{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:If you use an improper coolant
mixture, your engine could overheat and be
badly damaged. The repair cost would not be
covered by your warranty. Too much water
in the mixture can freeze and crack the engine,
radiator, heater core, and other parts.
If you have to add coolant more than four times a
year, have your retailer check your cooling system.
Notice:If you use extra inhibitors and/or
additives in your vehicle’s cooling system, you
could damage your vehicle. Use only the
proper mixture of the engine coolant listed in
this manual for the cooling system. See
Recommended Fluids and Lubricants on
page 402for more information.
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Checking Coolant
The surge tank is located on the driver’s side of
the engine compartment. SeeEngine
Compartment Overview on page 280for more
information on location.
{CAUTION:
Turning the surge tank pressure cap when
the engine and radiator are hot can allow
steam and scalding liquids to blow out
and burn you badly. Never turn the surge
tank pressure cap — even a little — when
the engine and radiator are hot.
The vehicle must be parked on a level surface.
When your engine is cold, the coolant level should
be near the cold ll line. When your engine is
warm, the level should be at the cold ll line or a
little higher.
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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 300
for 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.
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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 on your
vehicle’s instrument panel. SeeEngine Coolant
Temperature Gage on page 173for more
information.You also have a check gage message and a
transaxle uid hot message. SeeCheck Gage
Message on page 184andTransaxle Fluid
Hot Message on page 183.
Notice:Driving with the CHK GAGE 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. Your vehicle could
be damaged and the damages might not
be covered by your warranty.
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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.
CAUTION: (Continued)
CAUTION: (Continued)
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.
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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.
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