Special Policy 98054(A) - Coolant Loss, Visible Coolant Leakage/Head Gasket Fail

This bulletin is being revised to update labor time information and to include additional parts information. Please discard Corporate Bulletin Number 98054 (Section 6 -- Engine).

General Motors has determined that some 1995 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L engine (VIN Code 4, RPO LN2) may develop a failure of the cylinder head gasket leading to external coolant leaks from the cylinder head gasket to engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odor of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

To correct this condition, a new cylinder head gasket will be installed.

Involved are all 1995 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with LN2 (VIN RPO 4) built from Start of Production to End of Production, which begins and ends with the following VIN breakpoints:

This special policy covers the condition described above for a period of seven years or 100,000 miles (160,000 km), whichever comes first, from the date the vehicle was originally placed in service, regardless of ownership.

The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring cylinder head gasket replacement as a result of cylinder head gasket failure that results in an engine coolant leak. It does not cover engine damage from continuing to operate the engine in an overheated condition after loss of coolant.

Customers were notified of this special policy on their vehicles by General Motors one week after the original bulletin was issued in October, 1998 (see copy of typical customer letter included with this bulletin -- actual divisional letter may vary slightly). Customers will NOT be notified of this bulletin revision.

Parts required to complete this repair are to be obtained from General Motors Service Parts Operations (GMSPO).

Customer claims for reimbursement on previously paid repairs to replace the cylinder head gasket that resulted in an engine coolant leak, are to be submitted by September 1, 2000. Repairs must have occurred within seven years of the date the vehicle was originally placed in service, or 100,000 miles (160,000 km), whichever occurs first. Owners must submit original documentation which reasonably confirms the amount of unreimbursed expense(s), a description of the repair, date of the repair, and the person or entity performing the repair.

CUSTOMERS FROM THE STATES OF CALIFORNIA, CONNECTICUT, VIRGINIA, AND WISCONSIN MUST SUBMIT REQUESTS FOR REIMBURSEMENT DIRECTLY TO (CHEVROLET/PONTIAC) PER INSTRUCTIONS IN THE OWNER LETTER.

If the work was done by someone other than a GM dealership the amount of reimbursement will be limited to the amount the repair would have cost GM to have it completed by a GM dealership. Dealers must receive the original paid receipts or invoices verifying the repair, the amount charged, proof of payment, and the date of payment of those charges by September 1, 2000.

Install a new cylinder head gasket using the procedure outlined in Section 6A2 or the Engine section of the appropriate Service Manual.

Important: Cylinder head flatness specification:

Notice: Never use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and the block. Abrasive pads will produce a fine grit that the oil filter will not be able to remove from the oil. THIS GRIT IS ABRASIVE AND HAS BEEN KNOWN TO CAUSE INTERNAL ENGINE DAMAGE. Also, abrasive pads may round the cylinder head edges or remove enough metal during cleaning to affect cylinder head flatness, both of which are known to affect the cylinder head gasket seal.

Coolant Fill Procedure

1. Loosen the engine coolant air bleed screw located on the top side of the engine coolant outlet, under the preplenum duct.
2. Add coolant to the surge tank until all the air is evacuated through the air bleed valve.
3. Tighten the air bleed valve screw.
4. Add five crushed cooling system sealing pellets, GM P/N 12378254, to the surge tank.
5. Fill the surge tank until the coolant is between the Full Cold and the Full Hot markings.
6. Install the pressure cap on the surge tank.
7. Block the drive wheels and firmly apply the parking brake.
8. Shift an automatic transaxle to Park or a manual transaxle to Neutral.
9. Run the engine at idle until the upper radiator hose is hot to the touch.
10. Allow the engine to cool. Observe the coolant level in the surge tank. The coolant should be at a level between the Full Cold and the Full Hot markings. If the coolant is below the Full Cold marking, add coolant to bring the level in the surge tank up to the Full Cold line.

Submit a Special Policy claim with the information indicated below.

Dear Chevrolet/Pontiac Customer:

As the owner of a 1995 Chevrolet Cavalier/Pontiac Sunfire equipped with a 2.2L engine, your satisfaction with our product is of utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you should experience problems with your vehicle.

This letter is intended to make you aware that some 1995 Chevrolet Cavalier/Pontiac Sunfire models with 2.2L engines may develop a failure of the cylinder head gasket that allows coolant to leak from the cylinder head gasket to the engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odor of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

Chevrolet/Pontiac is providing owners with special coverage. If the above mentioned condition occurs within seven (7) years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, your vehicle will be repaired for you at no charge.

This is not a recall campaign. Do not take your vehicle to your Chevrolet/Pontiac Dealer as a result of this letter unless you believe that your vehicle has a condition as described above.

(Statement for all states except as shown below.)

If you have already paid for some or all of the cost to have the cylinder head gasket replaced and the in-service time and mileage were less than seven (7) years and 100,000 miles (160,000 km), you should contact your Chevrolet/Pontiac Dealer to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, and the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair by September 1, 2000.

(Statement for California, Connecticut, Virginia, and Wisconsin)

If you have already paid for some or all of the cost to have your cylinder head gasket replaced and your in-service time and mileage was less than (7) years and 100,000 miles (160,000 km), you should write the appropriate Division to seek reimbursement. Please provide your original pad receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. This information must be provided within two (2) years after the date on which you paid for the repair.

Repairs and adjustments qualifying under this special coverage must be performed by a Chevrolet/Pontiac dealer. Repairs may be performed by any authorized Chevrolet/Pontiac dealer that is authorized to sell and service Chevrolet/Pontiac vehicles. You may want to call the service department at the dealer to find out how long they will need to have the vehicle so that you may schedule the review at the most convenient time for yourself. This will also allow your dealer to order parts if they are not in stock. Keep this letter with your other important glovebox literature for future reference.

We regret any inconvenience that you may experience, however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet/Pontiac-GMC Division

General Motors Corporation

Enclosure