General Information: Other Saturn VUE I

Arrows and Symbols

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

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VIN Derivative

All engines and transmissions are stamped or laser etched with a partial vehicle identification number (VIN), which was derived from the complete VIN. A VIN derivative contains the following nine positions

VIN Derivative

A VIN derivative can be used to determine if a vehicle contains the original engine or transmission, by matching the VIN derivative positions to their accompanying positions in the complete VIN

VIN Positions

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The vehicle certification label is permanently located on the rear edge of the driver's door. Refer to this label in order to obtain the following information

1. The Gross Vehicle Weight Rating (GVWR)
2. The Gross Axle Weight Rating (GAWR), front and rear

The Gross Vehicle Weight (GVW) must not exceed the Gross Vehicle Weight Rating (GVWR).

The GVW is the weight of the vehicle and everything the vehicle carries. Include the following items when figuring the GVW

1. The base vehicle weight (factory weight)
2. The weight of any added vehicle accessories
3. The weight of the driver and the passenger
4. The weight of any cargo being carried

The front and rear Gross Axle Weights (GAW) must not exceed the Gross Axle Weight Ratings (GAWR), front and rear.

The GAW is the weight exerted on one of the axles (front or rear).

Scheme 5

The Tire Placard label is located on the front edge of the driver's side rear door in the coupe or the rear edge of the driver's side rear door in the sedan. Refer to the placard in order to obtain the following information

1. The maximum vehicle capacity weight
2. The cold tire inflation pressures
3. The tire sizes original equipment tires
4. The tire speed ratings original equipment tires

Scheme 6

The engine code letter is the eight digit of the VIN, which identifies the engine.

Stick-on labels attached to the engine, laser etching, or stamping in the engine block indicate the engine unit number/build code date.

The primary location for the engine ID is on front of the rocker cover (1).

The primary (2) and secondary (3) hand stamp locations for the Vehicle Identification Number (VIN).

Scheme 7

The engine identification (ID) number is located on the left side rear of the engine block (1).

Digits 1 thru 5 identify the engine type.

Digits 6 thru 12 identify the engine serial number.

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Scheme 10

Locations for vehicle identification number for the 5 speed M86 getrag manual transmission assembly (1).

Labeling - Anti-Theft

Note. The anti-theft label found on some major body panels MUST be covered before performing any painting, rustproofing or undercoating procedures. The mask must also be removed following those procedures. Failure to follow these precautionary steps may result in liability for violation of the Federal Vehicle Theft Prevention Standard, and subject the vehicle owner to possible suspicion that the part was stolen.

Scheme 11

Federal law requires Saturn to affix a label to certain parts on selected vehicles with the Vehicle Identification Number (VIN). The purpose of this law is to reduce the number of motor vehicle thefts by helping in the tracing and recovery of parts from stolen vehicles. The certification label on the driver's door qualifies as a theft deterrent label.

The theft deterrent label will be permanently affixed to an interior surface of the part and will contain the complete VIN. The label on replacement parts will contain the letter R, the manufacturer's logo, and the acronym for the Department of Transportation (DOT). DO NOT deface, or remove these labels.

Scheme 12

The service parts identification label is placed on the vehicle in order to help the service and parts personnel identify the vehicle's original parts and the vehicle's original options.

Scheme 13

The service parts identification label is located on the Left hand rear door.

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.

RPO Code List

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.

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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 15

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.

Registered and Non-Registered Trademarks

Scheme 16

The lock system used for the Saturn vehicle is a one key system with a key profile that has a two-sided cut and milled grooves that are unique to the Saturn lock system. The teeth of the key locate the tumblers and sidebar, flush to the outside of the lock cylinder from both sides of the cut.

Cutting Keys

The Saturn approved key cutting tool requires adapter kit SA9703B-3. The kit consists of a 10-position spacing plate, only positions two through ten are used, and a key insert. To install the adapter kit to the key cutting tool, follow the steps in the instruction manual provided with the key cutting tool.

The customer information card or the retailer records will show the key code as a four-digit numeric code. To determine the actual cut sequence of the key for this code, look up the code in the appropriate Key Code book. The cut sequence will be shown to the right of the code listing. The ignition cut sequence should be used to cut new keys, as it has all of the cuts necessary for the key to work properly in all the locks on the vehicle.

Determining Key Code

1. Insert the key in the Saturn approved key cutting tool with the tip of the key against the stop.
2. With the cutting die in the down position, move the carriage toward the die until it bottoms out. Record the depth 1, 2, 3, or 4.
3. Repeat for each position.

Lock Service Kit

The Saturn lock service parts are packaged in small packages and are disassembled. The door lock cylinder, rear compartment lid lock, liftgate lock, glovebox lock, and ignition lock service units are all available this way. The lock cylinder service units have all the parts necessary to build up a lock cylinder except the tumblers and the tumbler springs. The lock service kit, normally found in the parts department, has the tumblers and springs necessary to build up the lock cylinder service unit to the customer's original key code. To determine the vehicle key code, refer to the key identification and usage section. The ignition module is also serviced and disassembled as a unit.

The lock service kit also contains the other components of the door, rear compartment lid, liftgate, and ignition lock systems such as clips, pawls, lock cylinder caps, shutters, and springs. This kit is provided so that the retail facilities will have the components necessary, at all times, to service the Saturn lock system and maintain its one key integrity for the Saturn customer.

Lock Cylinder Tumblers

Each of the 4 depths on the key has corresponding tumblers, sometimes referred to as plates or wafers. The numbers are stamped on the tumblers for identification. Door and liftgate tumblers and ignition tumblers represent 3 different series. There are also three different compression springs. It is essential that the correct components be used in the tumbling of locks. The compression springs are inserted into the springs wells, and then the correct tumblers are inserted into the tumbler wards for the door and liftgate. The ignition is tumbled differently. Insert the correct tumbler into the tumbler wards then insert the tumbler springs on top of the tumblers.

Ignition Lock Cylinder Coding

Tools Required: J 41340 Lock Cylinder Holding Fixture and Staking Tool

1. Insert the appropriate tumbler (3) according to the key code into the corresponding tumbler ward.
2. The tumblers will not immediately seat into position because the sidebar has been pre-assembled. The tumblers will have to be pushed past the sidebar with a small flat screwdriver or pocket knife.
3. The tumbler springs (2) should then be inserted into the spring wells in the cylinder (4) where they will sit on top of the tumblers.
4. The seal plate (1) will be installed and crimped.
5. Insert the seal plate locator legs into the receptacle slots in the cylinder-seal plate will seat into position only when the two locator legs have been properly inserted into the receptacles on the cylinder.
6. While holding the seal plate in position with the thumb, insert the key into the cylinder and watch for the side bar to drop. If the side bar does not drop, the lock is tumbled wrong and you need to start over.
7. Ensure that the side bar does not drop on an angle. The side bar must be completely flush to the cylinder diameter.
8. Stake (1) the two metal areas of the cylinder (2) directly over the seal plate legs with a hammer and punch or chisel.
9. Repeat this stake on the areas of the cylinder directly opposite of the first to stakes.

Door Lock Cylinder Coding

1. Handing is determined by color of pawl. Orange is left hand and green is right hand.
2. Insert the appropriate tumbler (5) according to the key code into the corresponding tumbler ward.
3. The tumblers will not immediately seat into position because the sidebar has been pre-assembled. The tumblers will have to be pushed past the sidebar with a small flat screwdriver or pocket knife.
4. The tumbler springs (4) should then be inserted into the spring wells in the cylinder (3) where they will sit on top of the tumblers.

Balance of Assembly

1. With key inserted into cylinder, insert cylinder into housing (2). This will hold the pawl (1) into position once the cylinder is inserted into the housing.
2. Shutter (8) and compression spring (6) are pre assembled to the cylinder in the service package.
3. Install the cap (9) by aligning the notch in the cap with the large drain slot in the housing and pressing the cap until it bottoms out and snaps onto the housing (2).

Liftgate Lock Cylinder Coding

1. Start at the position nearest the front of the cylinder (8)-also begin with the side with four spring holes (7).
2. Select the correct tumblers for the desired code by the number stamped on the tumbler.
3. Install tumblers into lock cylinder.
4. Depress tumblers and insert key into lock cylinder. If lock cylinder is coded correctly, tumblers will be flush with cylinders.
5. Insert lock cylinder into housing and align tumblers with the two channels inside housing.
6. Remove key.
7. Install shutter springs (2), shutter (3) and cap (4).
8. Install Pawl (1) and retainer clip (3).

Balance of Assembly

1. Insert cylinder (8) into housing (4).
2. Place compressor springs (3) into head of cylinder (4).
3. Place shutter assembly (3) onto cylinder by snapping legs of shutter into place of cylinder.
4. Install the cap by aligning the notch in the cap with the large drain slot in the housing and pressing the cap until it bottoms out and snaps onto the housing.
5. Install lever onto cylinder end and place clip (3) onto lever to hold lever. Clip is formed to fit into position.
6. Place clip on lock assembly with legs up and snap over cylinder tail.
7. Use a file push on legs to snap clip into correct position.
8. Install rod clip onto lever by inserting small end into lever and forcing the clip to snap in tightly.

Glove Compartment Door Lock Cylinder Coding

1. Select the correct lock tumblers for the desired code by the number stamped on the tumbler.
2. Install lock tumblers (2), by applying downward pressure until locked into position.
3. Check coding of lock cylinder (4). Insert key.

Lifting and Jacking the Vehicle

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.

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Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads 6.69 in (170 mm) from the front pinchweld flanges.

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads 2.17 in (55 mm) from the rear pinchweld flanges.

Under the Center of the Rear Suspension

Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.

Supporting the Vehicle with Jackstands