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Vehicle safety record

2004 Chevrolet Aveo Problems, complaints & recalls

Owners have filed 206 complaints about the 2004 Chevrolet Aveo with NHTSA, most often about the engine & cooling (83) and the electrical system (37). Those complaints describe 23 crashes, 9 fires, 20 injuries and 2 deaths. It is covered by 2 recalls, the latest in May 2014 for the headlights. For comparison, the 2005 has 235.

NHTSA data checked

CAbout as many problems as a typical Aveo year, for its age

#66 most complained-about 2004 vehicle

Complaints
206
Recalls
2
Crashes
23
Fires
9
Injuries
20
Deaths
2

Most common 2004 Chevrolet Aveo problems

Share of all 206 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.

2004 Chevrolet Aveo recalls 2

Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do

Exterior lighting: headlights

14V261000218,000 vehicles affected

The problem
General Motors is recalling certain model year 2004-2008 Chevrolet Aveo vehicles equipped with daytime running lights (DRL). In the affected vehicles, there may be heat generated within the DRL module located in the center console in the instrument panel, which could melt the DRL module.
The risk
If the DRL module melts due to the heat generation, it could cause a vehicle fire.
The fix
GM will notify owners, and dealers will install a revised DRL module, inspect the wiring connector for heat damage, and clean the DRL circuit grounds. Owners were sent interim notices on August 14, 2014. The recall began on February 6, 2015. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet). General Motors recall number for this campaign is 14236.

Seat belts: rear / other

04V40700032,301 vehicles affected

The problem
On certain passenger vehicles, the rear safety belt can become twisted.
The risk
If this occurs the safety belt retractor may lock in position so that the belt cannot be used. In the event of a vehicle crash, personal injury to the seat occupant could occur.
The fix
Dealers will install a safety belt webbing guide to prevent the belt from twisting. The recall began on october 15, 2004. Owners should contact chevrolet at 1-800-630-2438. Vehicle owners located in guam should contact gm customer assistance at 1-671-648-8453.

What owners say

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206 complaints about the 2004 Chevrolet Aveo

Newest first, as filed with NHTSA by owners. Page 1 of 9.

AirbagsWheels & tiresCrash1 injury

Takata recall. On october 13th 2018 I was in a horrific accident while on the highway was an single car accident my tire shredded but still maintained air and my airbags didn't deploy on either side and I got a broken nose and a few facial fractures. Now I have severe headaches everyday since then.

Filed Incident Air bags · WheelsNHTSA 11234617
Visibility & wipers

What's with aveo's passenger side windshield wiper? It skids off the window and wipes the trim. When I first bought my car I thought someone made a mistake and put on the wrong size. When they needed replaced, I replaced the whole arm with a set matching maker specifications. And made no improvement at all. The tip of the passenger side wiper still swings clear off the window. Did somebody make off with the designer's ruler? Any chance they might give it back? I'd really like a windshield wiper that fits; don't really need one for the trim...

Filed Incident Visibility / wiperNHTSA 11155289
Engine & coolingFire

Tl* the contact owns a 2004 chevrolet aveo. While driving 45 mph, smoke appeared under the hood. The contact stated that the coolant pump housing fractured and coolant leaked out, which caused the smoke. The vehicle was not taken to a dealer to be diagnosed or repaired. The manufacturer stated that the vehicle was not under warranty and suggested taking the vehicle to a dealer. The failure mileage was approximately 116,000.

Filed Incident EngineNHTSA 11132146
Electrical system

Ignition switch is overheating. The longer the car is driven (10-15 miles) the hotter it is becoming. It heats up so much that the ignition key becomes quite hot as well...But the switch itself is even hotter. I fear there will be an electrical fire starting soon, and have already decided to stop at intervals to turn the ignition off so it cools down. It doesn't make any difference if it's driven fast or slow, driving still heats up the ignition switch. The only odd occurrence that might be somehow connected is the right turn signal bulb needed replaced since this started.

Filed Incident Electrical systemNHTSA 11112274
Electrical system

Tl* the contact owns a 2004 chevrolet aveo. The contact stated that while driving at various speeds, the vehicle would suddenly shut off when pressing the accelerator pedal. The vehicle was taken to haley automotive group dealer located in richmond, va but the cause of the failure could not be determined. The manufacturer was notified of the failure. The failure mileage was 91,000. ...Updated 08/31/17 *bf *js

Filed Incident Electrical systemNHTSA 11010734
Acceleration & cruise controlEngine & cooling

While backing up my vehicle I shifted the transmission from drive to reverse. The engine immediately accelerated to approximately 500 rpm. I immediately put my foot on the break, shifted to neutral, and turn the ignition to off. I was able to immediately restart to vehicle with no problem. This has happened before two or three times. Onetime while the vehicle was in drive and I had to press hard on the break and shut off ignition to avoid an accident. I seems like it mostly happens when it is cold outside ( in the 30"s f) . I think this is an unsafe situation and an accident waiting to happen.

Filed Incident Vehicle speed control · EngineNHTSA 10935088
Airbags

Tl* the contact owns a 2004 chevrolet aveo. The contact stated that the air bag warning indicator remained illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 140,390. Updated 09/22/16*lj *js

Filed Incident Air bagsNHTSA 10883634
Wheels & tires

Tl* the contact owns a 2004 chevrolet aveo equipped with milestar ms932 (na) tires, size: 185/65/r14 (na). While driving 65 mph, the contact heard a loud boom sound and the vehicle veered left without warning. The contact was able to pull the vehicle over to the side of the road and observed that the sidewall of the rear driver side tire was blown open. The tire was not diagnosed or replaced. The contact stated that the dot number of the tire was not included in nhtsa campaign number: 15t004000 (tires). The manufacturer was not notified. The vin was unknown. The vehicle failure mileage was 120,000 and the tire failure mileage was 12,000.

Filed Incident TiresNHTSA 10873854
Electrical system

Tl* the contact owns a 2004 chevrolet aveo. The contact stated that the key became stuck in the ignition switch. Due to the failure, the vehicle could not be turned off. The vehicle was taken to an independent mechanic who stated that the failure might be due to a defective gear shaft or ignition switch. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure mileage was 71,500.

Filed Incident Electrical systemNHTSA 10873192
Transmission & drivetrainEngine & cooling

I am on a fixed income. I bought this car used with 22,000 miles on it which I intended to take care of and drive for years to come, in fact into the ground. The manual I received with the car indicated that the timing belt should be replaced at 100,000. I live in a rural area where you really need a vehicle. I had driven to another town for a medical appointment. While traveling at 55 mph the car just died in heavy traffic in a 55 mph zone. I was lucky that a good samaritan helped me out of the dangerous condition...

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I was in on the road. My vehicle had 65,321 miies on it. I had to have the car towed to a dealer. It was determined the timing belt broke causing valve damage. I was told it would cost $5,000 to repair it which is what I paid for the vehicle. I did not having $5,000 so I junked the car. This ordeal caused significant problems for me financially, emotionally and physically. I was 62 at the time. The website carcomplaints has 56 similar complaints related to 2004 chevy aveos. All of the timing belts failed below 100,000 miles. There are similar complaints for the 2005 chevy aveo. Why wasn't I notified about this problem so I would not lose my shorts on my vehicle. I could have been killed. The event was terribly frightening. I suffer from heart failure. My new car payment is very hard to deal with on a fixed income. I took excellent care of the car. I should have been contacted about such dangerous condition. I would like some answers.

Filed Incident Power train · EngineNHTSA 10850538
AirbagsCrash

The vehicle was moving at a highway speed of approximately 65 mph, when it got into a collision with another vehicle. The other vehicle made an abrupt stop on the highway in front of the 2004 chevrolet aveo, which caused the aveo to hit the back of the suddenly stopped vehicle. Upon impact, the airbag did not deploy, which from my understanding should happen when traveling at that speed. In fact it especially should have deployed, due to the fact that the impact damaged the front of the vehicle. My concern is that I have bought two other vehicles from the same manufacturer since my purchase of this vehicle. I want to make sure that my family is safe when riding in these vehicles.

Filed Incident Air bagsNHTSA 10821804
Electrical system

2004 Chevrolet aveo. Consumer writes in regards to several vehicle repair problems. *Smd the consumer stated there was a burning odor coming from the vehicle. The dealer was unable to find a problem. A repair shop, replaced a fuse, due to know battery power. *Jb

Filed Incident Electrical systemNHTSA 10691432
Electrical systemFuel systemFire1 injury

Tl* the contact owns a 2004 chevrolet aveo. When starting the vehicle, the fuel tank caught fire. The vehicle was towed to a dealer where it was diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The contact extinguished the fire. A police report was not filed. The contact sustained pneumonia. Medical attention was required. The manufacturer was made aware of the failure. The approximate failure mileage was 80,000.

Filed Incident Electrical system · Fuel / propulsion systemNHTSA 10806240
Engine & cooling

2004 Chevrolet aveo. Consumer writes in regards to warranty notice #14093 issues. *Smd the dealer informed the consumer, the warrany had expired. Also, the water pump and timing belt were replaced. *Jb

Filed Incident Engine and engine coolingNHTSA 10726061
Engine & cooling

2004 Chevrolet aveo. Consumer writes in regards to vehicle timing belt failure. *Smd the consumer stated the vehicle stopped with no warning. *Jb

Filed Incident Engine and engine coolingNHTSA 10679178
Electrical system

Basically I am writing because gm issued a recall in june 2014 letting me know that my car has an issue which may lead to a fire in my car. The problem is that a year has passed and the status of that recall still is "general motors will provide its plan for remedying the defect as soon as it is confirmed." I honestly feel they have forgotten all about it. I don't think this should be an issue that should take such a long time to get fixed.

Filed Incident Electrical systemNHTSA 10766321
Lights

Tl* the contact owns a 2004 chevrolet aveo. The contact received notification of nhtsa campaign number: 14v261000 (exterior lighting); however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was not notified of the issue. The contact had experienced a failure.

Filed Incident Exterior lightingNHTSA 10761184
Seats & seat belts

This is just one problem...The car had major problems in the past like dying totally on a highway but that's not my concern right now. The back seat belt is locked up & it will not retract. I have a child so it's really inconvenient.

Filed Incident Seat beltsNHTSA 10722536
Engine & cooling

Timing belt snapped at 73k miles while driving 70mph on the highway. Total loss of power: steering, brakes, and gas pedal all not responding. Manually managed to coast to a stop on the highway shoulder with my emergency lights on, and without hitting or being hit by anything else. I'm alive and so is my passenger, but I fear we could have died on that day. Related tsbs and nhtsa below to augment reporting this problem. ---- Tsb #3936 / nhtsa id #10020573 states that this can happen prior to 60k miles to...

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others as far back as 2006; total engine loss due to damage from the belt at high speed not reported or fixed. Suggested maintenance also is not acceptable for this part: # tsb #060601021 -- timing belt inspection, maintenance, worn, wear.*Kb (nhtsa id #10020843, october 01 2006)

Filed Incident EngineNHTSA 10721552
Electrical system

I have a 2004 chevy aveo and a 2005 chevy cobalt my ignition switch on my aveo does the same thing as cobalt but aveo not recalled itook cobalt in dealer replaced ignition swtich took aveo in for recall for drl switch dealer wants over 300.Oo dollors to replace ignition switch I will be driving along at different speeds car will shut off starts back up when I put key in have to move key several times to start car dealer says no recall on the aveo for ignition switch but it is doing the same thing as my cobalt did is this a different switch the aveo has done this several times over the last year or so.

Filed Incident Electrical systemNHTSA 10721238
Engine & coolingCrash

In mid-february after one of our many blizzards, my wife was driving her sedan home. There was a pile of snow on our street that had hardened over. I guess she miscalculated its height (and hardness) and when she went over it, the car lurched up and she heard a loud grinding sound against the undercarriage. The engine started shaking immediately and within seconds died. She called me out and I took a look at the car. It was dead. I walked over to the ice and it was rock hard, so I tried to take a shovel to it and...

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immediately emailed my neighbors to be careful of it. I am not mechanically-inclined, so when I googled what might've happened, I saw several comments that it could be as minor as a damaged oil pan that causes the engine to shut down. Figuring it might be something minor, I called aaa (had to wait a few days since their lines were down) and had the car towed down the street to a service station. I was not expecting the assessment from the mechanic: apparently during the collision, the timing belt slipped and caused the pistons to bend. This would cost several thousand to fix. Unfortunately, this car has an "interference" design which is prone to extensive damage when this happens. Many aveo owners have complained about this online. The worst part about all of this is that even though it happened during a collision, our insurance chalked this up to "wear and tear" and we were forced to junk the car. Our car had less than 60k miles on it and we kept it in good condition. This should not have happened. This should have either been handled through a manufacturer recall or my insurance should have treated it as the collision it was and covered it.

Filed Incident EngineNHTSA 10712712
LightsFire

Tl* the contact owns a 2004 chevrolet aveo. The contact received notification of nhtsa campaign number: 14v261000 (exterior lighting). The contact called the authorized dealer several times for months and they indicated that the part was not available and that the repair was not urgent. Upon starting the vehicle, gray smoke started to emit from under the hood into the interior of the vehicle. The contact released the hood latch quickly and had a passenger disconnect the battery. However, a fire erupted near the...

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front of the vehicle as smoke filled the vehicle causing poor visibility that impacted the contact's breathing. The contact and the driver were able to quickly exit the vehicle. The contact was able to extinguish the flames with a fire extinguisher. A police report was not filed. The manufacturer was made aware of the failure. The vehicle was not repaired and was parked at the contact's residence. The failure mileage was not available.

Filed Incident Exterior lightingNHTSA 10703610
Lights

Tl* the contact owns a 2004 chevrolet aveo. The contact received notification of nhtsa campaign number: 14v261000 (exterior lighting); however, the part needed to do the repair was unavailable. The manufacturer was made aware of the failure. The contact experienced an intermittent failure with the exterior lighting. The failure mileage was unknown.

Filed Incident Exterior lightingNHTSA 10703520
Electrical system

Received a recall notice for drl fire hazard. Called 3 dealerships in the dallas area to have the mosfet repaired. All 3 dealership deny any knowledge of the recall and do not have the parts in stock even if I did bring the recall notice in. Chevy has sent 2 e-mails but they are the do not reply. I have attempted numerous times to contact chevy customer service and cant get anyone to respond. This is a fire hazard, please help me to get this fixed. *Tr

Filed Incident Electrical systemNHTSA 10684270
Electrical systemLightsCrashFire

Tl* the contact owned a 2004 chevrolet aveo. The contact received notification of nhtsa campaign number: 14v2610000 (exterior lighting). While driving approximately 40 mph, the contact's vehicle tapped another vehicle. The contact noticed flames under the hood of the vehicle. The vehicle became engulfed in flames and was destroyed. There were no injuries. The manufacturer was not notified. The vin was invalid. The approximate failure mileage was 150,000.

Filed Incident Electrical system · Exterior lightingNHTSA 10683015

Chevrolet Aveo: every year compared

YearComplaintsRecallsCrashesFiresTop problemGrade
200816311716AirbagsC
200721622513AirbagsD
200618911316Electrical systemC
200523511917Engine & coolingD
20042062239Engine & coolingC
All Aveo years

2004 Chevrolet Aveo vs rivals

More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.

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Questions about the 2004 Chevrolet Aveo

Does the 2004 Chevrolet Aveo have any recalls?

Yes - NHTSA lists 2 recalls for the 2004 Chevrolet Aveo: headlights (May 2014); rear / other (August 2004). Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.

What are the most common problems with the 2004 Chevrolet Aveo?

By the complaints owners filed with NHTSA, the most common problem areas are the engine & cooling (83), electrical system (37), airbags (23).

How many complaints has the 2004 Chevrolet Aveo had?

206 complaints have been filed with NHTSA, the first on February 26, 2004 and the latest on July 24, 2019. Of these, 23 describe a crash and 9 a fire, and together they report 20 injuries and 2 deaths.

Is the 2004 Chevrolet Aveo a reliable vehicle?

Its Safety Index is 41 out of 100 (grade C: about as many problems as a typical Chevrolet Aveo year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.

Which Chevrolet Aveo years have the most complaints?
What should I do if my 2004 Chevrolet Aveo has a problem?

If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.

Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data

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