Cracked Cylinder Head on 1994 SL1

My SL1 has a cracked cylinder head at 73,000 miles. The repair will
cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
the warranty was extended by Saturn because of the defect. However, my
car is 10 years old and out of the extended 6 yr. warranty. Has anyone
had Saturn pay for some of these costly repairs even though the car is
out of warranty?

In article >,
says...
> My SL1 has a cracked cylinder head at 73,000 miles. The repair will
> cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
> the warranty was extended by Saturn because of the defect. However, my
> car is 10 years old and out of the extended 6 yr. warranty. Has anyone
> had Saturn pay for some of these costly repairs even though the car is
> out of warranty?
>

Effects the cheaper SOHC engines only, not the Twincams. Stop going to
the dealer for price quotes. They, as in all dealers, always charge at
least twice the amount of a what a reputable shop would. (a new create
motor would be just over 2 grand) If you hit the right repo auction you
can buy a 96 or so SL2 Twincam for less than $2000 with about the same
amount of miles.

There are a lot of SOHC heads on eBay as well.

Lane [ lane (at) evilplastic.com ]
---
Visit my Saturn Car Audio and Performance Page at http://www.evilplastic.com



"Blah blah" > wrote in message
...
> In article >,
> says...
> > My SL1 has a cracked cylinder head at 73,000 miles. The repair will
> > cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
> > the warranty was extended by Saturn because of the defect. However, my
> > car is 10 years old and out of the extended 6 yr. warranty. Has anyone
> > had Saturn pay for some of these costly repairs even though the car is
> > out of warranty?
> >
>
> Effects the cheaper SOHC engines only, not the Twincams. Stop going to
> the dealer for price quotes. They, as in all dealers, always charge at
> least twice the amount of a what a reputable shop would. (a new create
> motor would be just over 2 grand) If you hit the right repo auction you
> can buy a 96 or so SL2 Twincam for less than $2000 with about the same
> amount of miles.

"Loretta" > wrote in message
om...
> My SL1 has a cracked cylinder head at 73,000 miles. The repair will
> cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
> the warranty was extended by Saturn because of the defect. However, my
> car is 10 years old and out of the extended 6 yr. warranty. Has anyone
> had Saturn pay for some of these costly repairs even though the car is
> out of warranty?

Here's my experience from a previous post in this ng:

> "Frank" > wrote in message
> om...
> > "Spongebob" > wrote in message
> >...
> > > I have a 1999 Saturn SL, 5 speed with just over 24000 miles. Since I
> bought
> > > it in February 2002, I have put on just under 8000 miles. My engine
> coolant
> > > light had been going off for a few days. I checked and replaced the
> coolant.
> > > Light went away, but came back a few days later. Had it checked out by
a
> > > mechanic I always go to (with previous cars as well), and he said,
"your
> oil
> > > is getting in the water, and the water is getting in the oil. You
should
> not
> > > be having this kind of trouble for having this low of mileage. Take it
> to
> > > the dealer and fight for this."
> > >
> > > So I go to the Saturn dealer in Clarence, NY. They look at it and they
> > > contacted my girlfriend (I was at work), and there is a crack in the
> > > cylinder head. That part alone is $950. Total cost of repairs with
> parts
> > > and labor is $2952.49. He said even though the car is out of
warranty,
> it
> > > has been his experience in the past that Saturn "MAY" participate for
> HALF
> > > because of the low mileage. All hoses/ pumps etc that have come in
> contact
> > > with the oil would need to be replaced. The radiator etc need to be
> > > flushed. He said the cam-shaft may need to be replaced but he is not
> > > definite on that at this time.
> > >
> > > This is outrageous. They did call back and tell her they will cover
> half. My
> > > warranty just ran out in March. The way I see it, and after
researching
> this
> > > issue all day while at work, and now, that there are other cars and
> people
> > > out there with this same issue, I should not have to pay a dime. If
> anyone
> > > knows anything more about this, and about this "flaw", please let me
> know,
> > > and any links to sites, or where I can find more info out.
> > >
> > > Thanks,
> > > Ian
> >
> >
> > Ian,
> >
> > I would investigate on the web the "secret warranties" and (also on
> > the web) the process of resolving issues like this through the small
> > claim courts (also search on "Saturn Sucks"). The are multiple
> > escalating steps that you need to take for both and there are websites
> > that coach you through this. Of course, nothing comes for free, with
> > this path, you will invest lots of time and your car may not be
> > fonctional for a while as you go through the initial steps.
> >
> > BTW, my dealarship (I'm from Ottawa, Canada) sells a complete "kit"
> > for this for CAN $1000 (US $650) (engine head, valves installed in the
> > head, spring, gaskets... you just swap or re-use your cam). I didn't
> > know about replacing all hoses and water pumps. I would have tought
> > that a cleaning/purge with Calgon detergent (like when I flush my
> > coolant system) would have sufficed but I can see how it might be
> > beneficial.
> >
> > Best of luck and please report back to us as you go along.
> >
> > Francis Marquis
> > 97 SL1, 97700Mi

"Spongebob" > wrote in message
...
> All is well. After my research I talked to the Service Manager the same
day
> I first posted this message, and said that "Half" would not be enough.
Then
> he let me speak with his manager (probably regional manager), and said
that
> Half is not good enough. He said that, "This is what they are doing in
this
> situation." And I said back to him, well obviously this isn't the first
time
> it has happened, since this is what they do in this "situation", and that
> 50/50 is not good enough since it is a reoccuring issue, and that there is
a
> "flaw" in the cylinders dating back to '91. I said that will all the info
I
> found out, that I will speak to whom ever I have to, to get this resolved.
> He said that he would again talk to the "Saturn people", but it was
unlikely
> that it would be free. I said "We'll see, and again I'll go above your
head,
> and whomever else I have to directly." He said he will be in touch.
>
> He calls me back the next morning, and said they will cover everything
> except for a "deductible" of $250. Whatever they want to call the $250
> payment, I don't care, b/c it is a lot better than 50/50, and certainly
> better than the full cost ($2952). So, it pays to do your research, to
stand
> your ground, and speak up. If I hadn't said anything, they would've taken
my
> $2952 without blinking. The car will done this Monday, or Tuesday at the
> latest.
>
> Thanks to all that replied to my post.
>
> Ian


Similar experience, here.
To be more specific (skip to next paragraph if you don't care <grin>): the
coolant low pressure light came on. I checked the coolant reservoir and it
was low. I bought the appropriate coolant (with DEX cool) per the owner's
manual and added about a 2 cup mixture of coolant and water. After about
five days, the coolant low pressure light again came on. I added another 2
cup mixture and scheduled an appointment with my Saturn dealer service
department. They found and fixed a low pressure condition but no oil in
coolant or coolant in oil. Another four or five days and the low coolant
light returned. Scheduled another appointment; this time they found coolant
in the oil. Service Manager and I discussed and decided to do nothing
further, since the recommended engine teardown and fix would likely cost in
excess of $2000, probably not worth my spending for a 64,000 mile-old car.
Finding this and other favorable postings in USENet, I decided to
escalate. Before doing so, I advised the dealer service manager, who
suggested I contact Saturn Customer Service. I did so, and within 24 hours
was phoned by an Area Manager from Spring Hill offering to pay for parts if
I paid for labor to fix the engine. The dealer service department did so,
charging me $1025.49 ($936.00 for labor and the rest for various parts, such
as the torque axis mount, not related to the cylinder head problem and about
which the service manager discussed with me ahead of time). The invoice
shows $960.10 in engine parts for which I was not charged.
While not pleased about having to pay anything to fix an engine problem
that should not have occurred so early in the engine's life, I'm much
happier than if I had to pay 11 times that amount for a new car. The engine
seems to be running very well.

(Loretta) wrote in message . com>...
> My SL1 has a cracked cylinder head at 73,000 miles. The repair will
> cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
> the warranty was extended by Saturn because of the defect. However, my
> car is 10 years old and out of the extended 6 yr. warranty. Has anyone
> had Saturn pay for some of these costly repairs even though the car is
> out of warranty?

My SL1 96 had this problem at 90Kmiles/7yr... total cost: 2200$CAN,
but arguing with the district manager, and showing all service records
from this car got them to pay 75% of the cost of a rebuilt head
(around 475$CAN)...

The car is now running OK, but transformed into an oil drinking
addict... 1 quart/2500Km. Not excessive, but was only 1/2 Quart/5000Km
before.

Blah blah > wrote in message >...
> In article >,
> says...
> > My SL1 has a cracked cylinder head at 73,000 miles. The repair will
> > cost over $2000! This problem occurs often in 1994 - 1996 Saturns and
> > the warranty was extended by Saturn because of the defect. However, my
> > car is 10 years old and out of the extended 6 yr. warranty. Has anyone
> > had Saturn pay for some of these costly repairs even though the car is
> > out of warranty?
> >
>
> Effects the cheaper SOHC engines only, not the Twincams. Stop going to
> the dealer for price quotes. They, as in all dealers, always charge at
> least twice the amount of a what a reputable shop would. (a new create
> motor would be just over 2 grand) If you hit the right repo auction you
> can buy a 96 or so SL2 Twincam for less than $2000 with about the same
> amount of miles.

Sure! And don't be surprised if that one has a casting flaw and cracks also!