Total Complaints
271 filings
CHEVROLET AVEO · model year
271 NHTSA complaints, 27 crash reports, and 2 active recalls for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2004CHEVROLETAVEO carries 271 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 27 crashes, 13 fires, 24 injuries, and 3 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 AVEO is engine and engine cooling with 31 filings, followed by electrical system (27) and engine (21). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 2 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.
NHTSA currently has 57 investigation files overlapping the 2004 AVEO, and 2 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
Total Complaints
271 filings
Crashes Reported
27 reports
Source
NHTSA ODI
Federal complaints database
Above median complaint volume — review patterns below.
| Component | Count |
|---|---|
| ENGINE AND ENGINE COOLING | 31 |
| ELECTRICAL SYSTEM | 27 |
| ENGINE | 21 |
| AIR BAGS | 15 |
| ENGINE AND ENGINE COOLING:COOLING SYSTEM | 14 |
| ENGINE AND ENGINE COOLING:ENGINE | 13 |
| EXTERIOR LIGHTING | 10 |
| SEAT BELTS:REAR/OTHER | 9 |
| POWER TRAIN | 9 |
| POWER TRAIN:AUTOMATIC TRANSMISSION | 8 |
| SEAT BELTS | 8 |
| STEERING | 6 |
| FUEL SYSTEM, GASOLINE | 5 |
| AIR BAGS:FRONTAL | 5 |
| VEHICLE SPEED CONTROL | 5 |
EXTERIOR LIGHTING:HEADLIGHTS
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.
SEAT BELTS:REAR/OTHER
ON CERTAIN PASSENGER VEHICLES, THE REAR SAFETY BELT CAN BECOME TWISTED.
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.
Mileage: 208,000
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.
Mileage: 208,000
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...
Mileage: 60,000
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.
Mileage: 116,000
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.
Mileage: 110,468
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
Mileage: 91,000
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.
Mileage: 85,250
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.
Mileage: 85,250
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
Mileage: 140,390
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.
Mileage: 120,000
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.
Mileage: 71,500
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
Mileage: 65,321
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
Mileage: 65,321
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.
Mileage: 130,200
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
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.
Mileage: 80,000
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.
Mileage: 80,000
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
2004 CHEVROLET AVEO. CONSUMER WRITES IN REGARDS TO VEHICLE TIMING BELT FAILURE. *SMD THE CONSUMER STATED THE VEHICLE STOPPED WITH NO WARNING. *JB
Mileage: 51,000
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.
Loss of motive power due to engine failure
Loss of Motive Power due to the Battery Energy Control Module
Electric Vehicle Battery Fires
Outboard Front Seat Belt Anchor Cable Failure
Fuel Line Leak
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.