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1996 Saturn SL Series CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Saturn REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Electrical Symbol Identification -> Domestic Vehicles
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
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BRAKE SERVICE PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
Hydraulic Brake Systems -> Troubleshooting -> Fluid Leaks -> Road Testing
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
When troubleshooting the hydraulic brake system, perform the following checks and inspections. If a malfunction still exists within the system, refer to the brake system diagnosis chart, Fig. , and the troubleshooting chart, Fig. .
Road Testing
When testing brakes, ensure the road is level and dry. Test brakes at both light and heavy pedal pressure. Do not lock up brakes or slide tires during a brake test.
Check the tires on the vehicle before performing a brake test. Tires should be equally infl...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Pressure Relief -> Except Aveo, LaCrosse, LeMans (1988-93), Malibu & Malibu Maxx (2004-05), Metro, Nova, Prizm, Spectrum & Storm -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strateg...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
- Depress brake pedal and loosen drive axle nut.
- Raise and support vehicle, then remove front wheel and tire assembly and front inner splash shield. If left drive axle or intermediate shaft is being removed, drain fluid from transaxle.
- Remove drive axle nut and washer, Fig. .
- Remove and discard lower control arm to steering knuckle cotter pin.
- Loosen lower control arm to steering knuckle castle nut to the point where top of castle nut is even with top of ball stud. Do not remove castle nut at this time.
- Separate lower control arm from steering knuckle, using a puller or removal ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
Starter, Replace
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
- Disconnect battery ground cable, then raise and support vehicle.
- Disconnect two electrical connectors and position aside, then remove two starter mounting bolts.
- Pull starter rearward and toward lefthand side of vehicle, then remove from vehicle.
- Reverse procedure to install, noting the following:
- Sta...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
General Motors Corp./Saturn Cars -> Check Gauge Warning Lamp ->
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
The Check Gauge warning lamp will light to warn the driver to inspect the oil pressure gauge, engine coolant temperature ga...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator using hose clamp pliers.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from thermostat housing using hose clamp pliers.
- Remove radiator outlet hose from thermostat housing and from vehicle.
- Reverse proced...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Saturn SL Series AUTOMOBILES
Serpentine Drive Belt, Replace -> Installation -> Removal
Vehicle: 1996 Saturn SL Series 1.9 L4 GAS
Removal
- Depress tensioner arm, using suitable 14mm or 9/16 inch wrench.
- Remove belt from A/C compressor and idler pulley, then remove belt.
Installation
- Route belt over a...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Saturn SL Series AUTOMOBILES
Component location diagrams for most 1996 Saturn SL Series cars and light trucks sold in the U.S. from 1990+.
Headlamp & Lighting Components Diagram for 1996 Saturn SL Series 1.9 L4 GAS Components on diagram: |
Front Of Engine Diagram for 1996 Saturn SL Series 1.9 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 Saturn SL Series AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Saturn SL Series cars and light trucks sold in the U.S.
1996 Saturn SL Series 1.9 L4 GAS Wiring Diagram Components on diagram: |
1996 Saturn SL Series 1.9 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Saturn SL Series AUTOMOBILES
OEM TSB listings for most 1996 Saturn SL Series cars and light trucks sold in the U.S. from 1985+.
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1996 Saturn SL Series 1.9 L4 GAS Auto Systems: |
Document: Car and Truck Fix It Right the First Time Issues Vehicle: 1996 Saturn SL Series 1.9 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Saturn SL Series AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Saturn SL Series cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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