Problems · by component

2004 Chevrolet Aveo electrical system problems

37 owner complaints to NHTSA about the 2004 Chevrolet Aveo cite electrical system, 18% of all 206 complaints for this model year.

Complaints
37
18% of all complaints
Crashes
1
Reported by owners
Fires
5
Reported by owners
Injuries
1
Reported by owners
01 —Owner reports

What owners say about the electrical system

Verbatim from NHTSA complaints, newest first
“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
“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”
Owner complaint to NHTSAFiled Jul 26, 2017Electrical systemODI 11010734
“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.”
Owner complaint to NHTSAFiled Jun 8, 2016Electrical systemODI 10873192
“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”
Owner complaint to NHTSAFiled Jan 4, 2016Electrical systemODI 10691432
“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.”
Owner complaint to NHTSAFiled Nov 23, 2015Electrical system, Fuel/propulsion systemFire reportedODI 10806240
“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.”
Owner complaint to NHTSAFiled Sep 21, 2015Electrical systemODI 10766321

Showing 6 of 37 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 10, 2026NHTSA vehicle page

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

Other 2004 Aveo problem areas