GM Service Manual Online
For 1990-2009 cars only

The following information covers the tests, inspections, and services required to retain the safety, dependability, and emission control performance of the vehicle.

Complete the necessary repairs and procedures on time. Use only the recommended fluids and lubricants. Refer to Fluid and Lubricant Recommendations .

Automatic Transaxle Shift Indicator Operation

Ensure that the indicator points to the gear chosen.

Horn Operation

Operate the horn occasionally to ensure the horn works.

Brake System Operation

Observe abnormal sounds, increased brake pedal travel, or repeated pull to one side when braking. If the brake warning light goes on, something may be wrong with part of the brake system. Have brake system inspected and repaired at once.

Restraint System Operation

Ensure all belts, buckles, latch plates, retractors, anchorages, and reminder systems are working properly. Look for any loose parts or damage. Notice anything that might keep a restraints system from doing its job, have serviced as necessary.

Exhaust System Operation

Observe any changes in the sound of the exhaust system or any smell of fumes. These are signs the system may be leaking or overheating. Have inspected and repaired at once.

Tire and Wheel Operation

Observe vibration of the steering wheel or the seat at normal highway speeds, or a pull to the right or left on a straight, level road. This may indicate the need for a tire pressure check. If the tire pressure is correct, and still notice any of these conditions, have vehicle serviced.

Steering System Operation

Observe changes in steering action. An inspection is needed when the steering wheel is harder to turn or has more free play than normal. If abnormal sounds are noted when turning or parking, the steering system should be inspected.

Observe any rattles or squeaks that may occur at different engine speeds or over different road conditions.

Headlight Aim Adjustment

Observe the light pattern occasionally. If beam aim appears different than normal, headlight adjustment should be checked.

At Each Fuel Fill

Perform the following underhood inspections at each fuel fill:

Engine Oil Level

Inspect the engine oil level and add the proper oil when necessary. Refer to Fluid and Lubricant Recommendations .

Engine Coolant Level and Conditions

Inspect the engine coolant level and add the proper coolant mixture. Refer to Fluid and Lubricant Recommendations .

Fluid Level Checks

Check the following fluid levels visually:

    • The windshield washer fluid
    • The brake fluid
    • The power steering
    • The coolant
        Add the proper fluid as needed. Refer to Fluid and Lubricant Recommendations .

Tire Inspection

Check the tires for damage, adequate inflation, and wear. Inflate the tires if necessary. If the tires show damage or wear, replace or rotate.

Hood Latch Operation

When opening the hood, note the operation of the secondary latch. It should keep the hood from opening all the way when the primary latch is released. Ensure the hood locks securely into place when it is closed. If the hood does not, service as necessary.

At Least Once a Month

Lamp Operation Check

Check the operation of the license plate lamp, side marker lamps, headlamps, including high beams, parking lamps, tail lamps, brake lamps, turn signals, reverse lamps, instrument panel illumination, and hazard warning flasher. Service as necessary.

Fluid Leak Check

After the vehicle has been parked for at least three hours, inspect the surface beneath the vehicle for signs of water, coolant, oil, fuel, or other fluids. If the air conditioning system was used, a small amount of water under the vehicle is normal. Notice fuel leaks or fumes, the cause should be found and corrected at once.

Cassette Tape Player Care

Clean cassette tape head after each 30 hours of play. Saturn cassette players have a clean indicator on the display which activates after approximately 30 hours of play.

Inspections to Complete After the Oil and Filter Have Been Changed

For convenience, the following inspection should be done when the wheels are removed for rotation:

Brake System Inspection

       Important: Inspect brakes more often if driving habits or conditions result in frequent braking.

    • Lines and hoses for proper installation, binding, leaks cracks, and chafing
    • Disc brake pads for wear and rotors for surface condition
    • Drum brake linings for wear and cracks
    • All the other brake parts, e.g., drums and wheels cylinders, includes ABS wheel sensor, etc.
    • Parking brake adjustment, Refer to Park Brake Adjustment .

Throttle Linkage Inspection

Inspect the throttle 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 and cruise control cables.

Transaxle Inspection

Inspect transaxle for fluid leaks. If the fluid leaks are present, have vehicle serviced.

At Least Twice A Year

Anti-Lock Brakes

If the vehicle is equipped with anti-lock brakes, refer to Diagnostic System Check - ABS .

Restraint System Check

Verify that the safety belt reminder light and all belts, buckles, latch plates, retractors, and anchorages are working properly. Look for any other loose or damaged safety belt system parts. Notice anything that might keep a safety belt system from doing its job, have it repaired. Have any torn or frayed safety belts replaced.

Look for any opened or broken air bag coverings, and have them repaired or replaced. The SIR system does not need regular maintenance.

Body Lubrication

Lubricate all of the following areas:

    • The door hinges and the hardware
    • The hood hinges, the safety lever, and the latch
    • The fuel door hinge
    • The rear compartment latches and the locks
    • The instrument panel compartment, the latch, and the lock cylinder
    • The console cover hinges and the latch
    • The seat hardware
        More frequent lubrication may be required when the vehicle is exposed to a corrosive environment. Refer to Fluid and Lubricant Recommendations .

At Least Once a Year

Movable Head Restraint Operation

Ensure the restraints stay in the desired position.

Setback Latch and Recliner Operation

On the folding seats, ensure the setbacks latch. Ensure the recliner is staying anchored by pushing and pulling on the top of the seat back while it is reclined.

Spare Tire and Jack Storage

Observe rattles in the rear of the vehicle. Ensure the spare tire, all jacking equipment, and any covers are securely stowed, according to instructions, at all times. Oil the jack lead screw, long threaded rod after each use. Ensure that the spare tire is properly inflated.

Weatherstrip Lubrication

Silicone grease on weatherstrips will make them last longer, seal better and not stick or squeal. Apply silicone grease with a clean cloth. During very cold, damp weather, more frequent application may be required. Refer to Fluid and Lubricant Recommendations .

Key Lock Service

Lubricate the key lock cylinders with the recommended lubricant. Refer to Fluid and Lubricant Recommendations .

Brake Transaxle Shift Interlock (BTSI)

Caution: When you are doing this inspection, the vehicle could move suddenly. If the vehicle moves, you or others could be injured.

Brake transaxle shift interlock the parking brake should be set and the key should be turned to the RUN position without starting the engine. Attempt to move the shift selector from the Park (P) position. The selector should not move until the brake has been depressed. Service as necessary.

Wiper Blade Refill Kit

Inspect wiper blades for wear or cracking. Replace the blade inserts that appear to be worn or damaged or that steak or miss areas of the windshield.

Starter Safety Switch Operation

    Caution: When you are doing this inspection, the vehicle could move suddenly. If the vehicle moves, you or others could be injured.

  1. Ensure enough room around the vehicle.

  2. Firmly apply both the parking brake and the regular brake.
  3. On automatic transaxle vehicles, try to start the engine in each gear. The starter should work only in PARK (P) or NEUTRAL (N). If the starter works in any other position, vehicle needs service.
  4. On manual transaxle vehicles, put the shift lever in NEUTRAL (N), push the clutch down halfway and try to start the engine. The starter should work only when the clutch is pushed down all the way to the floor. If the starter works when the clutch is not pushed all the way down, service vehicle.

Steering Column Lock Operation

While parked, try to turn the key to OFF in each shiftier position. The key should turn to OFF only when the selector is in Park (P). Service as necessary.

Parking Brake and Transaxle Park

Caution: When you are doing this check, the vehicle could begin to move. You or others could be injured and property could be damaged. Make sure there is room in front of the vehicle in case it begins to roll. Be ready to apply the regular brake at once should the vehicle begin to move.

To check the parking brake, follow this procedure:

  1. Park on a slight downhill grade.
  2. Apply the brake pedal.
  3. Fully apply the parking brake. The red BRAKE light should come on when the ignition is turned to the RUN or ACC position.
  4. With the engine running and the transmission in Neutral (N), slowly let up on the brake pedal until the car is held in place by only the parking brake.
  5. If the parking brake will not hold the vehicle or the BRAKE light does not stay on have vehicle serviced.

    To check the automatic transaxle Park (P) mechanism holding ability, release all brakes after shifting the transaxle to Park (P).

Underbody Cleaning

At least every spring, clean the underbody with water to remove any corrosive substances used for ice and snow removal and dust control. Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being cleaned.

Underhood Cleaning

Do not use abrasive cleaners, like chrome polish to clean engine and its components.

Engine Cooling System Inspection

Inspect and test the protection against overheating and freezing. If the coolant is dirty or has a rusty appearance, drain, flush and refill with new coolant. Keep it at the 50/50 mixture. Refer to Approximate Fluid Capacities . This provides proper freeze protection, corrosion inhibitor level, and engine operation temperature.

Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, fittings and clamps, replace as needed. Carefully clean the outside of the radiator and the air conditioner condenser to avoid damage to their fins. Wash the filler cap and neck.

To help ensure proper operation, a pressure test of the cooling system and pressure cap is recommended at least once a year.