Problems · NHTSA complaints

2004 Chevrolet Aveo problems

Owners filed 206 complaints about the 2004 Chevrolet Aveo with NHTSA between Feb 2004 and Jul 2019. The most-cited component is engine and engine cooling (62).

Complaints
206
Filed with NHTSA
Crashes
23
Reported by owners
Fires
9
Reported by owners
Injuries
20
People reported injured
Deaths
2
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  1. Engine and engine cooling62
  2. Electrical system37
  3. Air bags23
  4. Engine21
  5. Power train18
  6. Seat belts18
  7. Exterior lighting12
  8. Steering9
  9. Fuel system, gasoline9
  10. Service brakes, hydraulic8
  11. Vehicle speed control6
  12. Structure6
  13. Suspension5
  14. Tires4

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

Data from NHTSA Complaints API · synced Nov 10, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
200423
200512
200619
200713
200816
200916
201030
201115
201211
20134
201417
201518
20167
20171
20183
20191

Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

Engine and engine cooling

62 reports1 fire
“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”
Owner complaint to NHTSAFiled Oct 28, 2015Engine and engine coolingODI 10726061

Electrical system

37 reports1 crash5 fires
“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.”
Owner complaint to NHTSAFiled Jul 18, 2018Electrical systemODI 11112274

Air bags

23 reports14 crashes
“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.”
Owner complaint to NHTSAFiled Jul 24, 2019Air bags, WheelsCrash reportedODI 11234617

Engine

21 reports1 crash4 fires
“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.”
Owner complaint to NHTSAFiled Sep 28, 2018EngineFire reportedODI 11132146

Power train

18 reports2 crashes
“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 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…”
Owner complaint to NHTSAFiled Mar 19, 2016Power train, EngineODI 10850538

Seat belts

18 reports2 crashes1 related recall
“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.”
Owner complaint to NHTSAFiled May 31, 2015Seat beltsODI 10722536
Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.