Haynes Saturn Vue 2002 thru 2007 Automotive Repair Manual 1563927640, 9781563927645

Citation preview

4,

co wvcooOoSoSoSo N oOpanelwoice)

N. ©S N mead Bh

Se

©©

fat

5

ant EDo “yy

%

eS

Keren es

hee

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/saturnvueautomot0000imho

Viv

629.287

SATURN

Imhoff,

Tim.

Saturn

Vue

manual

/

bLUY

Ae

2002-07

automotive

repair

Saturn VU Automotive Repair Manual by Tim Imhoff and John H Haynes Member of the Guild of Motoring Writers

Models covered: Saturn VUE - 2002 through 2007 Does not include information specific to hybrid models

ABCDE FGHIJ KLMNO PQRST

& AUTOMOTIVE

ry

A

PC ISOeCIRNES MEMBER MeSeinnon Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England Haynes North America, Inc VICTORVILLE

CITY

LIBRARY

TSOl te CrnrcLle sD. Victorville, CA 92395 760-245-4222

AVUW

Acknowledgements Wiring diagrams provided exclusively for Haynes North America, Inc. by Valley Forge Technical Information Services.

© Haynes North America, Inc. 2009 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN-13: 978-1-56392-764-5 ISBN-10: 1-56392-764-0 Library of Congress Control Number: 2009924816 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

09-352

Contents Introductory pages About this manual Introduction to the Saturn VUE Vehicle identification numbers Recall information Buying parts Maintenance techniques, tools and working facilities Jacking and towing Booster battery (jump) starting Automotive chemicals and lubricants

0-5 0-5 0-6 0-7 0-8 0-8 0-15 0-16 0-17

Conversion factors Fraction/decimal/millimeter equivalents

0-18 0-19

Safety first! Troubleshooting

0-20 0-21

Chapter 1 Tune-up and routine maintenance

1-1

Chapter 2 PartA Four-cylinder engine

2A-1

Chapter 2 Part B 3.0L V6 engine

2B-1

Chapter 2 Part C 3.5L V6 engine

2C-1

Chapter 2 Part D General engine overhaul procedures

2D-1

Chapter 3 Cooling, heating and air conditioning systems _

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions and engine control systems

6-1

Chapter 7 PartA Manual transaxle

TA-1

Chapter 7 Part B Automatic transaxle

7B-1

Chapter 7 Part C Transfer case

7C-1

Chapter 8 Clutch and driveline

8-1

Chapter 9 Brakes

9-1

Chapter 10 Suspension and steering systems

10-1

Chapter 11 Body

11-1

Chapter 12 Chassis electrical system

12-1

Wiring diagrams

12-17

Index

IND-1

Haynes mechanic and photographer with a 2005 Saturn VUE

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead

costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Sec-

tion you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Sec-

tion 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the referenc® will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, “see Section 8” means in the same Chapter. References to the left or right side of the vehicle assume you are sitting in the driver’s seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING -

A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Saturn VUE This manual covers the Saturn VUE. These vehicles feature either an in-line fourcylinder engine or a V6 engine. The engine drives the front wheels via independent driveaxles. On AWD models, the rear wheels

are also propelled by way of a transfer case, driveshaft, rear differential and two rear ’ driveaxles.

Transaxles are either a five-speed manual or a four or five speed automatic. In addition, early four-cylinder models may be equipped with a continuously-variable transaxle that doesn’t use shifting functions. Suspension is independent at all four wheels, MacPherson struts being used at the front and coil springs with shock absorbers at

the rear. The rack-and-pinion steering unit is mounted on the subframe. The brakes are disc at the front and drums at the rear, with power assist standard. Some models are equipped with an Anti-Lock Brake System (ABS).

0-6

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to correctly identify the component required.

Registration. It contains information such as where and when the vehicle was manufac-

tured, the model year and the body style.

Certification label The certification label is attached to the driver's door post (see illustration). The plate contains the name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and the certifica-

Vehicle Identification Number

(VIN) This very important identification number is stamped on a plate attached to the dashboard inside the windshield on the driver’s side of the vehicle (see illustration). It can also be found on the certification label located on the driver’s side door post. The VIN also appears on the Vehicle Certificate of Title and

tion statement.

Engine number On four-cylinder

models,

the engine

the right end of the valve cover, and through a partial VIN etched into the bowl around the oil filter (see illustrations). On 3.0L V6 engines,

the number is stamped near the oil pan rail on the rear of the engine. On 3.5L V6 engines, it's stamped near the transaxle on the radiator side of the engine.

Transaxle number There are four transaxles used on these

models. All have important information, such as the transaxle type and build date, on a metal tag that is attached near the center top of the unit. Some models also have a prominent sticker that gives similar information.

identification number is found on a sticker on

338

Bu

298

a) 13008

$.83N0 qynneas

S —92812 KH a Ss SS BS

Q334$

StHS SUHSA HE 3i%0 co

=

ie x

%= m ~
] ENGINE CONTROL MODULE (ECM) wt

=

re}

|(EXCEPT 3.5L)

|POWERTRAIN CONTROL MODULE (PCM) (3.5L)

|

| |

L | ces UNDERHOOD FUSE BLOCK

Chapter 12 HOT IN RUN

HOTAT

OR START

HOT AT

ALL TIMES

q

|

ALL TIMES

HOT AT

INSTRUMENT PANEL

HOT

ALL TIMES

FUSE BLOCK (IPFB)

IN RUN

CLUTCH ote

,

ENGINE/ COOLING

/

|

SS

Sa

Y

DK GRN/| WHT

{ K+ ca DIODE

uy

7

|

40A

FAN

he

a

Ole

Se

a RELAY

Y

A

|

ae i

BLOWER RELAY ]

be

| er

hee

+

HVAC

ruse 10A

nut (upper arrow), remove the distributor

5

and remove the three adapter retaining

bolts (arrows)

‘ oy) 4 ae eer i ie: f ¥

i

$

‘

: Z

3

:

ao

the seal

on

:

:

:

|

i

ee oh

a!

:

isis

‘

(

2

a

Pa

sod

BAetalFionn aS P

;

fe Bk

re fer :

SEs

:

{

ifit

3

| Sat }

he i

Beer

z

M e

1

as

3

t

.s,

|

|

| i

a

Ne

en

927645

:

‘

aco

MM

oe =.

| ,

3

i

NE

#

See

es

for i st BER

;

= _ Does not incllide| information specific Ke} hybrid models Ve

cuts

§ * Seer ye

‘ }:

~ ee

t

\| |

t

ae be!

Re &

s

!

¢ »: is

é

e c4

:

ISBN-1 3: 978-1 -56392-764-5

» .

i

l

oe

j>

-

: $ =

-

‘ i

|\)

N

le

.

| i '

‘i

.

¢ Bie e

ee

‘ Fae

a"

r

use

? 4

-

(closed valve)

the end of the camshaft

5

Easy*to OAs

(pe

has the corresponding camshaft lobe pointing away from tine rocker arm

j

¢t

(1

yt

by Peod

10.1 When performing the freeplay test,

damage the sprocket positioning pin on

i

ae

a

make sure the adjuster that’s being teste”

cam seal into place with a hammer and a large socket, but make sure you don’t

camshaft turn as the bolt Is tightened)

pad r

fi e

A S

te

:

you can also drive a

3; ea

2 beans

i,

ra

,

lent

\ i 72" uke) aal—maal~leiarelalle; : Fi Mig

9.7b As a last resort,

|

‘pbasedona. g beets

y

:

5

bt, F

9.7a You can press a new seal into place

}

3

job easier and eliminate the need for specia} tools : eS

y

Es

-

aw

-

g

7

:

Pi

ont

yl

:

ins

ean

’

‘

E

e

: e _Haynestti ps*gi ve

ee ire through the ep Te TiGOWy. aie pushing the check ball down (see illustration)

i

Se

Qi

teard OW ra} U Si ral