Info - New Model Features and Service Guide

This bulletin is being revised to provide updated information. Please discard Corporate Bulletin Number 06-00-89-011 (Section 00 -- General Information).

This is a special bulletin to introduce the new Saturn Sky. The purpose of this bulletin is to familiarize you with this vehicle's features and describe the actions that your Service Department will need to take to ensure that you are able to fully service this exciting new model.

The purpose of this section is to familiarize you with the technical aspects of this vehicle. It is important to know that the Sky is built on the all new Kappa platform. The Sky is Saturn's first venture into the roadster segment.

Powertrain

The Sky comes equipped with a 2.4L (LE5) DOHC Variable Valve Timing L4 engine (VIN Code B). The LE5 produces 177 hp and 166 lb ft of torque. The LE5 engine is matched with an Aisin AR5, 5-speed (RPO MA5) manual transmission and a rear differential with a final drive ratio of 3.91.

The Saturn Sky manual transmission and clutch have been set up to be durable, easy to launch at start, and easy to operate shifting gears. This transmission may exhibit a clunk noise when shifting gears at low speeds. The noise may be present during low speed driving maneuvers, such as driving in stop-and-go traffic or in parking lots, which require declutching and shifting. Some amount of driveline clunk is normal due to the design characteristics of the driveline system. Refer to Corporate Bulletin Number 05-07-29-005A for more information.

Please take the time to go over the proper operation of a manual transmission vehicle to prevent inadvertent abuse conditions from occurring. In addition, it is suggested that you go over some of the key cautions on manual transmission operation with the new owner.

The Saturn Sky automatic transmission has a 4th gear ratio of 1:1 and a 5th gear (overdrive) ratio of 0.75:1. The shift indicator positions are PRND4IL.

PARK (P): This position locks the rear wheels. It is the best position to use when you start the engine because your vehicle cannot move easily.

Ensure the shift lever is fully in PARK (P) before starting the engine. Your vehicle has an automatic transmission shift lock control system. You must fully apply your regular brakes before you can shift from PARK (P) when the ignition key is in RUN. If you cannot shift out of PARK (P), ease pressure on the shift lever. Push the shift lever all the way into PARK (P) while pressing the button on the shift lever as you maintain brake application. Then move the shift lever into the gear you wish.

REVERSE (R): Use this gear to back up. At low vehicle speeds, you can also use REVERSE (R) to rock your vehicle back and forth to get out of snow, ice or sand without damaging your transmission.

NEUTRAL (N): In this position, the engine does not connect with the wheels. To restart when you are already moving, use NEUTRAL (N) only.

AUTOMATIC OVERDRIVE (D): This position is for normal driving. If you need more power for passing, and you are:

The transmission will shift down to a lower gear and have more power.

FOURTH (4): This position is also used for normal driving. However, it offers more power and lower fuel economy than AUTOMATIC OVERDRIVE (D).

Here are examples for using FOURTH (4) instead of AUTOMATIC OVERDRIVE (D).

INTERMEDIATE (I): This position is also used for normal driving. However, it offers braking from the engine for slight downgrades where the vehicle would otherwise accelerate due to steepness of grade. If repetitive shifts occur between third and fourth gears on steep hills, this position can be used to prevent repetitive shifting. Fuel economy will be lower than AUTOMATIC OVERDRIVE (D). A time you might choose INTERMEDIATE (I) instead of AUTOMATIC OVERDRIVE (D) is when driving on hilly and winding roads.

LOW (L): This position gives you even more power but lower fuel economy than INTERMEDIATE (I). You can use it on very steep hills, or in deep snow or mud. If the shift lever is put in LOW (L), the transmission will not shift into Low gear until the vehicle is going slowly enough.

Suspension

The Sky rides on a 4-wheel independent suspension with Bilstein Monotube Shock Absorbers, P245/45R18 Goodyear Tires, 18-inch aluminum wheels, four-wheel disc brakes with a 95.1 wheel base and a front track of 60.5 inches and rear track of 61.2 inches.

Power Steering

The Sky features an engine accessory belt driven power steering pump and power rack and pinion steering.

Brakes

The Sky comes standard with ABS four-wheel disc brakes that feature 11.6 inch (296 mm) vented front discs and 10.6 inch (270 mm ) solid rear discs and dynamic rear proportioning.

Wheels and Tires

There are two different styles of 18-inch wheels, painted aluminum and chromed aluminum that come equipped with P245/45R18 Goodyear tires. With the wide wheel and the low profile tire, during the assembly process, the tire pressure may be over or under inflated to obtain a proper wheel to tire seat. The tire pressure must be checked and set to the recommended level, as noted on the tire label located on the driver's door, prior to delivery to the customer. The Sky does not come equipped with a spare tire. A tire inflator and seal kit is located in the trunk.

Electrical Architecture

The electrical architecture of the vehicle is GMLAN* and requires the use of a CANDi module to communicate with the Tech 2®. There are potentially 13 different modules that can be found on the Sky. Refer to Data Link References and Control Module References in for a list of modules, as well as links to schematics, repair instructions and programming, data link references and set-up information.

*GM Local Area Network

Radio

The Sky is equipped with the new GM Black Tie Radio. The three radios offered are:

UC1 - AM/FM base with single CD player

US8 - AM/FM up-level with CD/MP3 player

US9 - AM/FM ICDX with CD/MP3 player

The US8 and US9 radios are equipped with a cooling fan to dissipate the heat generated by the radio amplifier. The fan will turn on when the radio internal temperature is above 70°F (21°C) and will turn off at 65°F (18°C). The fan will continue to run with the key off until the radio temperature is at or below 65°F (18°C).

Both the ignition key and radio must be on prior to setting the time and/or date. Refer to Corporate Bulletin Number 06-08-44-004 for more information.

Battery/Charging System

The battery is located under the hood on the passenger side of the vehicle. Should it be necessary to jump start the vehicle, use the remote positive terminal and the negative terminal located in the passenger side of the engine compartment. If you need to remove the battery, you must remove the right front fender.

Express Down Window

The driver's window has an express-down feature which allows the window to lower all the way without continuously pressing the switch. Press the front of the switch all the way down and release. To stop the window while it is lowering, pull up on the front of the switch momentarily.

Convertible Top

The Sky has a manually operated convertible top. For water management, there is a bladder and drains in the trunk. The bladder and drains must be free of obstructions to assure proper drainage. On the trunk where the top buttress latches, there is a paint protection patch. Do not remove this paint protection ; it is there to protect the trunk from becoming scratched by the top buttress.

Care must be taken when lowering or raising the top. There are areas on the top that may pinch your fingers or hands during top operation.

Lowering the Manual Convertible Top

1. Park on a level surface and set the parking brake. Shift an automatic transmission into PARK (P) or a manual transmission into REVERSE (R).
2. Make sure the ignition is turned off and lower the windows.
3. Push the trunk release button located in the glove box, or on the remote keyless entry, if equipped
4. Lift the trunk.
5. The convertible top front latch, located above the inside rearview mirror, must be unlatched. Pull the latch down and turn it counterclockwise to unlatch it. Leave the latch open and rotated to prevent damage.



6. Pull rearward on the side edge (B) of the convertible top and pull it off of the windshield frame.
7. Push the convertible top down into the trunk (D).

•	After the top is stored, apply one even push, as shown, on the convertible top to ensure that the top is fully retracted and securely stored.

•	Close the trunk (D) by pressing down on it with a swift, firm motion.

Raising the Manual Convertible Top

1. Park on a level surface and set the parking brake. Shift an automatic transmission into PARK (P) or a manual transmission into 1st (1) or REVERSE (R).
2. Make sure the ignition is turned off and lower the windows.
3. Push the trunk release button located in the glove box, or on the remote keyless entry, if equipped
4. Lift the trunk.
5. Pull the front edge (A) of the convertible top forward from the outside of the vehicle, or push the front edge (A) of the convertible top forward from the inside of the vehicle.
6. Turn the top front latch handle clockwise to latch the convertible top.



7. Close the trunk lid (D).
8. At the rear edge of the convertible top, press down on the two buttresses (C) to position them into the top of the trunk.

Closing the Hood

Notice: To help avoid hood and door damage, close both doors before closing the hood.

Driver Information Center (DIC)

To operate the DIC, if equipped, the ignition switch must be in the "Run" position. The DIC is controlled through two buttons located on the steering wheel. The DIC messages will be shown on the instrument panel cluster display.

Personalization Features

The following features can be accessed in order by pressing the MENU button anytime while the vehicle is in ON. Pressing the INFO and RESET/SELECT buttons at the same time provides the MENU switch function. Press the MENU button to scroll through each option. All of the personalization features may not be available on your vehicle. Only the features available will be displayed on your driver information center (DIC).

When the desired option is reached, use the RESET/SELECT button to toggle between the modes of that option. To make a selection, press the MENU button again. If no selection is made within 10 seconds, the display will revert back to the previous information displayed.

The MENU mode is exited when the INFO button is pressed, a 10 second time period has elapsed, the ignition is turned to OFF, or the end of the MENU list is reached.

The purpose of this section is to familiarize you with some of the unique characteristics of the vehicle. The following functions may operate differently than what the customers are used to and are considered normal.

Automatic Headlamp Control

The Sky is equipped with an Automatic Lamp Control system which automatically turns the headlamps and other exterior lamps on at dusk or when necessary. The exterior lamps can also be operated manually. The I/P backlight is not integrated in the headlamp switch. The automatic lamp control system must determine if it's dark enough to turn I/P backlights on.

The Automatic Lamp Control system's light sensor is located on the top of the instrument panel. It is important to avoid placing any objects on or near the sensor, or covering up the sensor.

Important: In rainy weather, etc., the customer may comment that they manually turned on the headlamps; however, the I/P lights did not come one. It is important to note that the I/P backlight will only turn on when indicated by the Automatic Lamp Control's light sensor. This condition is not related to the headlamp switch function, BCM or I/P function. This is considered a normal condition and no parts should be replaced.

Rear Window Defogger

The button for the rear window defogger is the right button located on the HVAC control head. When you start the engine and depress the rear window defogger switch, the defogger cycle lasts for 15 minutes. Further operation will result in 7.5 minute defogger cycles. The rear window defogger cycle resets to 15 minutes when the ignition is cycled from OFF to ON.

The rear window defogger cycle time is suspended and the defogger will continue to run anytime the vehicle obtains speeds of 50 mph (80 km/h) or above. When vehicle speed is reduced below 50 mph (80 km/h) the rear window defogger cycle time will continue.

Important: Do not turn on the rear window defogger if the convertible top is down.

HVAC System Air Flow

Your vehicle has flow-through ventilation. Flow through ventilation allows outside air to be forced through your ventilation system when your vehicle is moving. Outside air will also enter the vehicle when the fan is running. Flow-through ventilation can be stopped in vent and bi-level modes by pressing the recirculation button.

Remote Keyless Entry

A Vehicle Locator feature has been added to the remote keyless entry. The vehicle must be turned off to operate this feature. Press and hold the "horn" button on the fob for approximately one second to locate your vehicle. The horn will sound 3 times and the headlamps and parking lamps will flash 3 times. Press and hold the button for 3 seconds to sound the panic alarm. The horn will sound and the headlamps and parking lamps will flash for 30 seconds. Press the button again to cancel the panic alarm. Press the button again or turn the ignition key to any position to cancel the panic alarm.

Trunk Release

The trunk release button can be found inside the glove box on the upper left panel of the box. The glove box is located on the lower right side of the instrument panel. If the trunk is ajar, there will be a light on in the instrument cluster along with a warning chime.

Windshield Wiper Operation

There are three wiper modes: Intermittent, Low and High. In the Intermittent mode the wipers adjust with your vehicle speed. Your wiper speed will increase as you drive faster and decrease when you slow down. Rotate the speed-sensitive intermittent adjustment band on the lever to increase or decrease the delay between intermittent wipes mode. It is important to note that the wiper timing will fluctuate with the vehicle speed.

If the vehicle speed is less than 50 mph (80 km/h), the wipers will toggle anywhere between low and 3 seconds between wipes. In certain weather situations, if vehicle speed is less than 50 mph (80 km/h), the customer may find it necessary to switch the wipers to the Low mode.

Power Mirror (RPO D48, if equipped)

The power outside rearview mirrors may be adjusted using the controls located on the door panel. It is important to press the control button at the 12 o'clock, 3 o'clock, 6 o'clock, or 9 o'clock position in order to move the mirrors. If the control button is pressed between these positions (arrows), the mirrors will not move.

Fuel Range Calculation

Important: Vehicle speed input is required to calculate the fuel range information. Therefore, the vehicle must be driven after re-fueling in order for the DIC to reflect the accurate fuel range information.

The fuel range information shown on the DIC is an estimated fuel range. Fuel range is estimated based on the current driving situation. The fuel gauge should be used to determine the actual fuel/distance remaining. Be sure to reset the fuel economy on the DIC before delivering the vehicle to the customer.

Accessory Power Outlets (APO)

The Sky is equipped with one APO, located on the console beneath the radio control head. If the vehicle is equipped with a "smoker's package", the APO will have to be converted to a cigarette lighter. If the cigarette lighter is used as an APO, it could result in a blown fuse.

Service Information

All required service information is currently online on GM SI. A dealership can also find the most current Owner Manual and Labor Time Guide online at website http://service.gm.com and under the Service Information link.

Effective with the 2007 Sky, Saturn will begin to use the GM Straight Time process for establishing labor times. Most labor operations will initially use straight time instead of published times. For key elements of the straight time process, refer to Corporate Bulletin Number 06-00-89-008.

Special Tool Requirements

The following new tools are essential to service the Sky:

Vehicle Maintenance

Oil Life Monitoring System -- It is important to reset the remaining oil life to 100% after each oil change.

Manual Transmission

It is not necessary to check the transmission fluid level. Check for leaks. A fluid leak is the only reason for fluid loss.

Approximate Fluid Capacities

The following approximate capacities are given in English and metric conversions. All capacities are approximate. When adding fluid, be sure to fill to the approximate level as recommended in this bulletin. Recheck the fluid level after filling.

The PDI form was revised for the 2005 model year to ensure that special attention is paid to the following areas (refer to Corporate Bulletin Number 04-00-89-028A).

* For dealers in Canada, the revised PDI form is available for download from the "GM World of Warranty" on the GMinfoNET.