NHTSA Complaint #10440907 — 1995 SATURN SW

SOHC LK0/L24 (FROM HTTP://EN.WIKIPEDIA.ORG/WIKI/SATURN_I4_ENGINE#SOHC_LK0.2FL24) THE SOHC (LK0/L24) CYLINDER HEAD HAD 8 VALVES AND WAS MADE OF LOST FOAM CAST ALUMINUM. THE CAMSHAFT WAS LOCATED IN THE CENTER OF THE CYLINDER HEAD AND DRIVEN BY A CHAIN OFF THE FRONT CRANKSHAFT SPROCKET. MOTION FROM THE CAMSHAFT WAS TRANSMITTED TO THE EIGHT VALVES BY THE HYDRAULIC LIFTERS AND ROCKER ARMS. THE LK0 ENGINE FIRST USED TBI (THROTTLE BODY INJECTION) FOR FUEL DELIVERY AND WAS RATED AT 85 HP (63 KW) AND 110 FTLBF (149 NM) OF TORQUE FROM 1991 TO 1994. THE L24 ENGINE RECEIVED MPFI (MULTI-PORT FUEL INJECTION) IN 1995 WHICH INCREASED POWER OUTPUT TO 100 HP (75 KW) AND 114 FTLBF (155 NM). THIS ENGINE WAS USED FROM 1995 TO 2002. THE SOHC ENGINE WAS AVAILABLE ON THE BASE MODEL S-SERIES VEHICLES (SC1, SL, SL1, SW, SW1) 1992 THROUGH 1998 L24 CYLINDER HEADS DEVELOPED ISSUES WITH CRACKS DEVELOPING IN THE FIFTH CAMSHAFT JOURNAL, LOCATED CLOSEST TO #4 CYLINDER. THE HAIRLINE CRACK WOULD DEVELOP BETWEEN THE OIL FEED PORT OF THAT JOURNAL AND THE COOLANT PASSAGES IN THE CYLINDER HEAD. SYMPTOMS WOULD RANGE FROM OVERHEATING TO LOW COOLANT, HOWEVER, MOST CARS AFFECTED BY THIS ISSUE EXHIBITED OIL MIGRATION INTO THE COOLING SYSTEM. THE RESULTING MIXTURE OF THE TWO FLUIDS WOULD RESULT IN A THICK BROWN "MILKSHAKE"-LIKE MIXTURE, VISIBLE IN THE COOLANT OVERFLOW TANK. SATURN RELEASED UNADVERTISED POLICY WHICH WOULD COVER THIS ISSUE, EXTENDING THE WARRANTY ON THE CYLINDER HEAD TO 6 YEARS OR 100,000 MILES (160K KM). REPAIR REQUIRED THE REPLACEMENT OF THE CYLINDER HEAD. AND FLUSHING OF THE COOLANT SYSTEM. BADLY AFFECTED CARS WOULD SEE COOLANT IN THE OIL, AS WELL AS OIL IN THE COOLANT, AND WOULD REQUIRE THE REPLACEMENT OF THE COMPLETE ENGINE ASSEMBLY. UNTIL THE CYLINDER HEAD CASTING WAS REDESIGNED ... *TR