2006 Saturn Relay Service and Repair Manual

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Covers all 2006 Relay trims — 3 Mini Passenger Van 4-Door, 2 Mini Passenger Van 4-Door ·
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2006 Saturn Relay service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • 3 Mini Passenger Van 4-Door
  • 2 Mini Passenger Van 4-Door

Engines covered

  • 3.9L 3880CC 237Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.5L 213Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #09E00500017/02/2009Component: STEERING

DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONSTM" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEM

Consequence

A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARN

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE T

NHTSA #05V55200007/12/2005Component: EQUIPMENT:OTHER:LABELS

CERTAIN TRUCKS AND SPORT UTILITY VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THESE VEHICLES WERE SHIPPED WITH TIRE AND L

Consequence

A MISPRINTED LABEL COULD LEAD TO IMPROPER VEHICLE LOADING SPECIFICATIONS OR TIRE INFLATION WHICH COU

Remedy

OWNERS WILL BE PROVIDED WITH CORRECTED LABELS AND INSTALLATION INSTRUCTIONS. AT THE CUSTOMER'S OPTI

TSB #11027947

This PI directs technician to training regarding sliding door operation.

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11019074

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019073

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019072

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11017252

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11011782

This Preliminary Information communication provides information to the technician about the use of J-35616-64B terminal test probe, replacement terminals, and terminated leads. The J-35616-64B is the latest test probe released for checking

Showing the 8 most recent of 242 technical service bulletins on file with NHTSA.

20060821Component: AIR BAGSCrash reported1 injured

DT*: THE CONTACT STATED THE VEHICLE WAS INVOLVED IN A COLLISION AND THE AIRBAGS DID NOT DEPLOY. THE CONTACT WAS STOPPED IN THE CENTER LANE, WHEN ANOTHER VEHICLE ATTEMPTED TO GET INTO THE SAME LANE.

20140105Component: AIR BAGSCrash reported

MY 18 YEAR OLD SON HAD AN ACCIDENT. HE ROLLED THE VAN MULTIPLE TIMES, HIT TREES ,DAMAGED ALL SIDES, AND ROOF OF THE VAN. THE ONLY DOOR THAT WOULD EASILY OPEN WAS THE DRIVERS DOOR. THE FRONT AXLE BROKE

20130213Component: ENGINE1 injured

TL* THE CONTACT OWNS A 2006 SATURN RELAY. THE CONTACT STATED THAT WITHIN THREE MONTHS, THE INTERIOR OF THE VEHICLE DARKENED BY THREE SHADES. THE CONTACT STATED THAT THERE WAS A STRONG METALLIC SMELL I

20171001Component: SERVICE BRAKES

SERVICE ABS AND SERVICE TRACTION CONTROL LIGHTS CAME ON AND HAVE REMAINED ON FOR SEVERAL DAYS. FURTHER MESSAGES CONTINUE FLASHING ON THE DRIVER INFORMATION CENTER. THIS HAS BEEN A RECURRING PROBLEM OV

20171001Component: ELECTRONIC STABILITY CONTROL (ESC)

SERVICE ABS AND SERVICE TRACTION CONTROL LIGHTS CAME ON AND HAVE REMAINED ON FOR SEVERAL DAYS. FURTHER MESSAGES CONTINUE FLASHING ON THE DRIVER INFORMATION CENTER. THIS HAS BEEN A RECURRING PROBLEM OV

Showing the 5 most serious of 32 complaints filed with NHTSA.

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