Features and Service Guide Part 2
A/C OperationUse the "AUTO" feature on both the fan setting and the mode setting. Also select a temperature setting that is higher in warm weather and lower in cooler weather.
If the "AUTO" feature is not utilized, minimizing the application of the A/C compressor will also improve economy. If for passenger comfort A/C is desired, use the "Hybrid Air Conditioning mode identified by the button with the green H next to the snow flake.
To improve passenger comfort during "Auto-Stop" turn on air recirculation on the HVAC control panel. This will not only improve the comfort in the vehicle, but will tend to allow "Auto-Stop" to last longer as the evaporator temperature will rise at a slower rate. Using recirculation will improve economy over use of the "Normal A/C" mode (single snowflake) with similar comfort.
Air delivery mode is also important when trying to minimize A/C compressor operation. As shown in the table, setting the air delivery to the windshield (Defrost) mode will force the A/C compressor ON, and disable "Auto-Stop" regardless of the operator-selected A/C mode. If possible, it is suggested to dial the air delivery one detent counter-clockwise, or 'one click back', from defrost to at least allow "Auto-Stop."
This table also shows that when the A/C mode is OFF (no LED), the A/C compressor will still be commanded ON anytime the air delivery is to the floor or rotated clockwise from "floor." This is to minimize window fogging. For an owner who wishes to maximize their fuel economy, selecting "one click back," or more, from "floor" will disable the compressor.
About the Vehicle
The purpose of this section is to familiarize you with the technical aspects of the Aura hybrid vehicle and introduce the major hybrid components. The following information will only define the differences between the base Aura and the Aura hybrid vehicle.
Hybrid Electronics
The primary components in the hybrid include:
The battery pack with the Battery Disconnect Unit located in the trunk area behind the rear seat.
36-volt DC power cable that routes under the vehicle from the battery pack to the generator control module. This and all other 36-volt wiring on the vehicle is contained within BLUE conduit to identify it and the associated components as "Intermediate Voltage."
Generator Control Module, mounted to the core support at the front left of the engine compartment. This is a water-cooled component that contains all of the electronics to convert 36-volt DC battery voltage to 12-volt DC, which drives the vehicle electrical load when the engine is in "Auto-Stop." Additionally, this component will convert 36-volt DC to 3-phase AC to drive the generator for "Auto-Start" and electric power assist modes of operation, as well as convert the 3-phase generator output to DC to charge both the 12- and 36-volt batteries
Generator, which appears as a conventional belt-driven generator, functions as both a 3-phase generator and motor, depending on if the vehicle is in a mode of charging the vehicles batteries, or boosting the engine's performance.
Engine
The engine included in the 2007 Aura Green Line hybrid is a 2.4L 4-cylinder (RPO LAT) rated at 164 hp at 6400 rpm.
This engine features Variable Valve Timing and coil on plug ignition - similar to the 2.4L used in the 2006 and 2007 ION.
This engine is equipped with a new accessory drive system with a 7-rib, high strength belt and a unique dual belt tensioner that allows the generator to drive the crankshaft in "Auto-Start" and assist modes, and allow the engine crankshaft to drive the generator in normal electrical generation and re-generation modes.
Smart Start
Unique to the hybrid Aura is an ECM-controlled "Smart Start" system. If the operator lightly "bumps" the ignition to the "start" position and returns to run, the starter will continue to run until the engine starts or a maximum crank time is reached.
Auxiliary Coolant Pumps
Two auxiliary coolant pumps are included in the design of the hybrid. One is used anytime the engine is running to circulate coolant through the starter/generator control module. The other is used to provide circulation of coolant through the heater core and will only be run while in "Auto-Stop" depending upon the outside air temperature.
Transmission
The transmission is a modified 4T45E (RPO ME7) transmission that includes an external auxiliary pump to maintain transmission line pressure, and therefore clutch activation when the vehicle is in 'Auto-Stop' mode. This transmission has other hybrid-specific content including a modified channel plate, spacer plate and valve body. Care when ordering service parts is required to reference the correct transmission RPO.
Brakes
The Aura Hybrid vehicle comes standard with ESC (Electronic Stability Control) as the base brake system.
The brake system has been modified for the hybrid vehicle. These modifications include the addition of a brake booster vacuum sensor, a brake hydraulic pressure sensor.
The brake booster vacuum sensor is mounted to the brake booster and provides booster vacuum status to the ECM. This input is used to either inhibit "auto-stop" or force an "auto-start" if the vacuum level is too low.
The brake hydraulic pressure sensor is an input to the ECM that is used to sense the pending release of the brakes. This is used by the ECM to command an "auto start" as the operator releases the brake. The ECM must "learn" the zero-pressure value when the ECM is either reprogrammed or replaced.
Tires and Ride Height
The hybrid vehicle is equipped with special, low rolling resistance Uniroyal Tiger Paw Touring SR P215//60R16 M+S tires. These tires are available through Saturn Service Parts (in Canada, the PDC).
IP Cluster
The IP cluster has a modified tachometer that includes an indication of "Auto-Stop" and "Off" to communicate these modes to the customer. A "Charge/Assist" gage is located on the right side of the cluster to communicate if the hybrid system is charging the battery, or if the hybrid system is assisting the engine in propelling the vehicle.
In some cases, an owner may wish to not have the "ECO" light illuminate. To disable the "ECO" light use the DIC buttons on the steering wheel. With the engine off and the key turned to accessory, set the DIC to the outside air temperature and odometer mode. Press and hold the reset button for several seconds. The light will come on solid and then flash several times and turn off to indicate that it is disabled. Repeat the procedure to enable the light. Turning the ECO light off only affects the operation of the green ECO telltale.
Additional DIC specific messages for the Aura hybrid are:
MPG (L/100 KM) INST (Instantaneous)
POWER STEERING
HOOD AJAR
SERVICE HYBRID
SRVC (Service) HILL START
HVAC Controls
The hybrid HVAC control panel is similar to the HVAC control panel in the Aura XR (C68). The unique feature with the Aura Hybrid HVAC control panel is the addition of an "Hybrid A/C" mode. The Hybrid A/C button features a green H next to a snowflake.
In the "Hybrid A/C" mode the operator is allowing the Auto-Stop hybrid function when the vehicle is at rest in drive. The Normal A/C mode is selected with single snowflake (left most button). In "Normal A/C", the operator requests no "Auto-Stop" mode.
The operator-requested A/C mode may be overridden by the HVAC system depending upon air delivery selection. When the Defrost air delivery mode is selected, Normal A/C will be commanded, disabling Auto-Stop regardless of the operator-selected A/C mode. Additionally, the A/C compressor will operate if the air delivery is selected anywhere from floor to the first detent back from defrost. This compressor operation is commanded in order to dehumidify the incoming air to avoid window fogging even when the A/C LED is not illuminated.
To maximize fuel economy the use of the "AUTO" selections for both Fan Speed and Air Delivery mode should be selected.
Vehicle Towing
The hybrid Aura should not be used to tow a trailer. It can be recreationally towed with all four wheels on the ground. For complete information on towing, refer to the latest copy of "Trailer, Recreational and Disabled Vehicle Towing Information," Corporate Bulletin Number 03-00-89-033E.
Extended Storage
If the Hybrid vehicle is to be stored for a period greater than 30 days, the 12-volt battery negative cable should be disconnected to protect both batteries from discharge.
Service Charging of Hybrid Battery Pack
The hybrid battery pack is designed to be charged by the hybrid system only. The hybrid system monitors the voltage and temperature of individual battery cells and controls the charging rate to optimize the life of the batteries. There is no provision at this time for "off-board" charging of the battery pack and such charging should not be attempted. In the event of a significant battery discharge, it may be necessary to replace the complete battery pack.
Technical Assistance
Menu Prompts (U.S. TAC Only)
The Technical Assistance Center has modified the telephone prompts to target hybrid Aura calls to a specialized group. After calling TAC at 877-446-8227, the caller will press 1 to "Speak to a TAC Consultant," press 2 for a "New Case," press 2 to NOT route to an Action Center, and continue to follow the prompts for "Hybrid." The last prompt will route by "Propulsion System" or "All Other Areas."
* Canadian Retailers: Calls relating to the Hybrid Aura should be directed to the Saturn/Saab group within GM Canada TAC.
Restricted Parts
Refer to Corporate Bulletin Number 07-06-01-005 for additional information regarding 2007 Saturn Aura Green Line hybrid restricted parts.
Many of the hybrid-specific electrical/electronic parts will be restricted for the six months, not allowing parts departments to order these parts. To obtain a restricted part, the service department will need to contact Technical Assistance who will assist in the diagnosis, document the issue and submit the parts order to Saturn Service Parts on behalf of the retailer.
For all the parts that are included in the following restricted list, it is important that these parts are not disassembled more than is necessary to remove them from the vehicle or more than the supplied replacement part. Further disassembly in the field may result in disturbing the assembly, therefore reducing the benefit of the parts restriction.
Hybrid Battery Assembly including Battery Back, Fan and Battery Disconnect Unit (BDU)
Motor Generator Unit
Starter Generator Control Module (SCGM)
Hybrid Pump Driver
36V Underbody Cable Assembly
Parts Serviced via the Electronic Service Centers (ESC)
The hybrid radios, IP clusters and DVD displays will be serviced through the Electronic Service Centers (ESC). Refer to the following bulletins and/or subsequent updates for ESC program part processing.
Corporate Bulletin Number 05-08-44-007C: Radio Ordering Process
Corporate Bulletin Number 05-08-49-009D: IP Cluster Ordering Process
Parts Return
Hybrid parts will be returned through the Warranty Parts Center (WPC) by request using the Saturn Failed Parts Return System. For additional information on the parts return process, reference the latest revision of Corporate Bulletin Number 05-00-89-042B - "Warranty Parts Center/Saturn Parts Return Program (U.S. Only)." Canadian Retailers should refer to Service Bulletin 99-00-89-019C for all Warranty Parts Center returns.
To help avoid personal injury, always ensure the ignition switch is in the OFF position and the ignition key has been removed prior to working on any 36V components. After the key has been removed, disconnect the negative 12V battery cable and then open the generator battery disconnect control module cover. After waiting for at least 5 minuets, measure the voltage potential using a DMM between the following:
36V positive and negative battery cable
36V positive battery cable and vehicle ground
36V negative battery cable and vehicle ground
All measured voltage levels must be below 3 volts. After confirming that voltage levels are less then 3 volts, remove the 36V negative and then the positive battery cable.
Battery Pack Special Handling Requirements
The battery pack should NOT be disassembled more than is necessary to remove it from the vehicle. Further disassembly in the field may unnecessarily subject the technician to potential personal injury and may result in disturbing the assembly and reduce the benefit of the parts restriction.
For return shipment of the battery pack (Hybrid Battery Assembly - P/N 15940523), additional special handling is required.
The "NONSPILLABLE" Label included with replacement battery pack must be installed on the failed part prior to return shipment to the Warranty Parts Center (WPC).
Protect the battery terminals from short circuit during shipping. Using a heavy cloth tape, cover the battery module negative and positive terminals, and cover the top portion of the exposed "Battery Disconnect Control Module." DO NOT TAPE OVER THE BATTERY DISCONNECT PLUNGER.
Package the part to be returned in the same container that was used that was used to deliver the replacement part. This container has specific labeling for a Class 8 hazardous materials that are exempt from a hazardous material classification for the purposes of transportation.
Special Tools
The "Compressor, Hydraulic Belt Tensioner," tool number EN48079, is the only required unique special tool.
Submitting Field Product Reports
As with any new vehicle, or vehicle technology, prompt detailed feedback on owner concerns and/or vehicle conditions in the field is of great value to the manufacturer.
U.S. Retailers: To provide Voice Mail reports on the product the retailer should reference the latest version of Corporate Bulletin Number 02-00-89-002E - Information for Dealers on How to Submit a Field Product Report (FPR).
Canadian Retailers: Submit Product Information Reports (PIRs) using the electronic PIR form located on the GMinfoNET.
Refer to the latest version of Corporate Bulletin Number 02-00-89-002F - Information for Dealers on How to Submit a Field Product Report (FPR).
End of Vehicle Life Recycling of Hybrid Battery Pack
In the event that a vehicle reaches the end of useful life and is due to be dismantled information on the recycling of the hybrid battery pack can be found at http://www.recyclemybattery.com.
Canadian Retailers: The above website link will direct you to a list of Commercial Battery Recyclers. GM is not recommending these recyclers nor is it an exhaustive list of available recyclers. Two such battery recyclers listed are Inmetco (www.inmetco.com) and Kinsbursky/Toxco (www.kingsbursky.com). These U.S.-based companies specialize in the recycling of batteries, including the Nickel Metal Hybrid (NiMH) type used in the Aura battery pack. Additional information an be obtained by contacting these companies directly via their respective websites. You are responsible for complying with all federal, provincial, and local laws and regulations relating to the shipment of the hybrid battery back. Please note that provincial and/or local laws can be more stringent than federal regulations, so be sure to check all three.