888000 miles/140000 km. Cylinder head is warped (?) - I still have not received a decent answer on this one. Head gasket is definately blown at left front corner of engine - same problem area as the last 2 repairs that "fixed" this problem. Head is replaced as-is and gaskets are all replaced. My cost is $855 CND.

There was a batch of 1995 Cavaliers/Sunfires that GM offered to fix up to 7 years/160000 km under Special Policy 98054A. I have now had this problem twice now after their initial repair so it obviously is not fixed or ignored another underlying problem with this engine.

GM's own Pontiac and Chevy dealerships have never heard of this model of engine failing in this manner. Independent machine shops and engine rebuilders that deal with this model of engine tell me that this is absolutely unheard of for that engine.

If you have this problem I recommend getting the full text of TSB 98054A. Interestingly enough, after GM does the original repairs on the head they dump a pack of leak sealer into the engine. I am not a mechanic but I understand that leak sealer is really a temporary patch that should never be needed on a low mileage engine that is operating properly, much less one that has just undergone a MAJOR repair to fix a coolant leak. My cynical brain tells me that GM knows that there is a defect in this engine, they did the minimum to patch it the first time then chucked leak sealer in it so it lasted until the warranty expired.

I am currently dealing with GM on this issue to try and get reimbursed for my repairs and to try and find a permanent solution to the problem. The same repairs have been done multiple times and failed multiple times - the problem is not being addressed. Feel free to contact me with any questions or other information you may have about this issue. Thanks.