General Information: Other Saturn Aura I

US English/Metric Conversion

Decimal and Metric Equivalents

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

Scheme 3

Customer Concern Verification Sheets

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally.

Dealers

All U.S. Dealers participating in the GM Common Training Program can enroll through the GM Common Training System Website at https://www.gmcommontraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about GM Common Training should contact the GM Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010.

Fleets

GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through GM Common Training/GM Service Technical College (STC).

Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmcommontraining.com using the "Contact Us" button on the site and/or the GM Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831.

Most GM STC course materials have associated charges.

To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831.

Non-GM Dealer Technicians

Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry.

ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information.

Scheme 4

The vehicle identification number (VIN) plate is the legal identifier of the vehicle. The VIN plate is located on the upper LH corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle

RPO Code List

The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Scheme 5

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

Scheme 6

A prevailing torque fastener may be reused ONLY if

1. The fastener and the fastener counterpart are clean and not damaged
2. There is no rust on the fastener
3. The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Metric Prevailing Torque Fastener Minimum Torque Development

English Prevailing Torque Fastener Minimum Torque Development

Thread Inserts

General purpose thread repair kits. These kits are available commercially.

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Key and Lock Cylinder Coding

The instrument panel (I/P) ignition lock cylinder uses 8 of the 10 key cut positions, 1-8 when counting from the key head. The tumbler orientations alternate in adjacent locations from side to side with 4 on each side.

1. Hold the uncoded cylinder assembly (1) positioned so the side with the retention lug is facing upward.
2. Insert one tumbler spring (2) each into each of the 4 tumbler spring holes.
3. The first tumbler to be loaded will be key cut position 2, the second number in the key code. Determine the cut depth at this position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly (1), the end where the key is inserted. It may be necessary to move the sidebar, already pre-assembled into the uncoded cylinder assembly, out slightly to fully install the tumbler into the correct slot.
4. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers (3) into the tumbler slots located at key cut positions 4, 6, and 8.
5. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching key into the cylinder assembly (1). All tumblers and the sidebar should be flush with the outside diameter of the cylinder assembly.
6. Rotate the cylinder assembly (1) so that the side with the retaining pin (4) hole is facing upward and then remove the matching key. Remember the tumblers (3) are not self-retaining and must be held in place.
7. Insert one tumbler spring (2) each into each of the 4 tumbler spring holes.
8. The first tumbler to be loaded will be key cut position 1. Determine the cut depth at this position and install the corresponding tumbler (3) into the tumbler slot nearest the front of the cylinder assembly.
9. In the same manner, determine the cut depth and corresponding tumbler and install the 3 remaining tumblers (3) into the slots located at key cut positions 3, 5, and 7.
10. Check for correct loading by holding the tumblers (3) in position and fully inserting the matching key into the cylinder assembly (1). All tumblers and the sidebar should be flush with the outside diameter of the cylinder assembly.
11. Lightly lubricate the tumbler (3) surfaces and the small detent recess on the side of the cylinder assembly (1) using the lubrication provided.
12. With the matching key fully inserted into the coded cylinder assembly, rotate the cylinder so that the side with the retaining pin (4) hole is facing upward.
13. Insert one retaining pin spring (5) and then one retaining pin (4) into the hole located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the coded cylinder is installed into the case assembly (6).
14. With the matching key fully inserted into the coded cylinder assembly and the retaining pin (4) fully depressed into the cylinder, align the retaining lug on the cylinder with the groove on the inside diameter of the case assembly (6). This groove extends the full length of the case assembly.
15. Install the coded cylinder assembly into the case assembly (6) being careful to hold the retaining pin spring (5) and retaining pin (4) in the cylinder until the retaining pin spring and retaining pin enter the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retaining pin snaps into place limiting the rotation of the cylinder assembly.
16. With the coded cylinder assembly in the Off-Lock position, insert the detent ball (7), if equipped, and detent spring (8) into the hole in the side of the case assembly (6). Install the anti-rattle spring (9) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (9) are fully seated, pressed into, the case assembly.
17. Remove the matching key and install the ignition cylinder bezel (10) onto the case assembly (6). Make sure the retaining clips of the ignition cylinder bezel are correctly positioned and fully snapped onto the case assembly.

Tools Required

J 43625 Lift Pad Adapter

Scheme 7

Note. Perform the following steps before beginning any vehicle lifting or jacking procedure: Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents.

Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads on the front lower brackets, inboard of the rocker pinch weld flange and outboard of the front frame rail, at the torque box location, as shown.

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rear frame rail, at the torque box location, as shown.

Vehicle Jacking

Note. When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points.

Front of Vehicle

When using a service jack under the front of the vehicle use one of the following locations

1. Place the service jack pad in the same location as shown for the front lift pads.
2. Under the front frame crossmember, as shown.

Rear of Vehicle

When using a service jack under the rear of the vehicle place the jack pad on the rocker panel flange, at the torque box location, as shown.