1996 CHEVROLET METRO

Typical onset: 80,000-140,000 mi

Symptoms: white smoke from exhaust on cold start, coolant loss with no visible leaks, oil looks milky or chocolate-colored, overheating in stop-and-go traffic, rough idle that smooths out when warm

Fix: Both head gaskets, resurface both heads (often warped 0.003-0.008 inch), new head bolts, timing belt while you're in there. 8-12 labor hours depending on engine. The 1.0L 3-cylinder is slightly easier due to fewer fasteners. Must pressure-test cooling system afterward and burp air pockets thoroughly or you'll overheat again.

Estimated cost: $1,200-1,800

Typical onset: 100,000-150,000 mi

Symptoms: slipping on 1-2 or 2-3 shift under load, delayed engagement into drive or reverse, whining noise that increases with speed, burnt ATF smell, no third gear or stuck in second

Fix: The 3-speed automatic is notoriously weak and overheats easily. Often the internal clutches glaze or the valve body sticks. Rebuilds rarely hold up—most techs recommend a junkyard replacement (2-3 hours swap) or converting to manual if the owner is handy. External oil cooler retrofits help but don't fix existing damage.

Estimated cost: $800-1,500

Typical onset: 90,000-160,000 mi

Symptoms: severe vibration at idle that wasn't there before, squealing or chirping from serpentine belt area, visible wobble of crankshaft pulley, check engine light for crankshaft position sensor code

Fix: The rubber isolator between the hub and outer ring deteriorates and the ring separates or spins freely. If it comes apart while driving, the serpentine belt shreds and you lose power steering, alternator, and water pump—engine overheats in minutes. Replacement is 1.5-2.5 hours including belt. Inspect this every oil change after 80k miles.

Estimated cost: $250-450

Typical onset: 70,000-120,000 mi

Symptoms: clutch pedal engages near the floor, grinding into first or reverse when cold, slipping under hard acceleration in higher gears, chattering on engagement in stop-and-go

Fix: Cable-actuated clutch stretches over time and the flywheel glazes from stop-and-go heat cycling. Full job is clutch disc, pressure plate, throwout bearing, resurface flywheel, new cable, and pilot bearing. 4-6 hours. The flywheel is often too thin to resurface after one previous job, requiring replacement. Manual transmission fluid change at same time prevents synchro wear.

Estimated cost: $600-950

Typical onset: 120,000-180,000 mi

Symptoms: loud ticking or tapping from valve cover that doesn't quiet with warmup, loss of power and fuel economy, check engine light for cam position correlation, metallic rattling on cold starts

Fix: The 1.0L SOHC uses rocker arms and the cam lobes wear if oil changes are skipped or wrong oil is used (needs 5W-30, not 10W-30). Requires camshaft replacement, all rocker arms, valve adjustment, new timing belt and tensioner, and valve cover gasket. 6-8 hours. Often find worn distributor drive gear on cam at same time. Preventable with religious 3,000-mile oil changes.

Estimated cost: $800-1,200

Symptoms: hard starting after sitting overnight, sputtering or stalling when fuel tank below 1/4, loss of power on highway acceleration, fuel pump whining louder than normal

Fix: Fuel tanks rust from inside out, especially in rust belt or coastal areas. Sediment clogs the sock filter on the pump and the inline filter. Inline filter is 0.5 hour, but if the tank is rusty, you're replacing pump, sender, and possibly the tank. Pressure-test fuel system before condemning pump. Use quality fuel filters every 30k miles as cheap insurance.

Estimated cost: $150-800