Most common 2004 Chevrolet Aveo problems
Share of the 206 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Chevrolet Aveo complaints by model year
Best Aveo years: 2010, 2011. Compare all years →
2004 Chevrolet Aveo recalls (2)
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.
Remedy: 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.
Seat belts › Rear/other
On certain passenger vehicles, the rear safety belt can become twisted.
Remedy: 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.
NHTSA defect investigations
Federal safety investigators have looked into 2 possible defects involving the 2004 Chevrolet Aveo:
Stuck throttle valve
On October 19, 2007, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged stuck throttle incidents due to ice formation within the engine air intake tract in certain model year (my) 2004-2005 Chevrolet aveo vehicles manufactured for sale or lease in the united states.this investigation was prompted by a safety recall campaign (05f-069) conducted by general motors corp.
Stuck throttle valve
To date, the office of defects investigation (odi) is aware of 29 non-duplicative complaints/field reports and 52 warranty claims related to the alleged defect affecting 69 unique subject vehicles.because the alleged defect condition is most likely to occur during winter months when ambient temperatures are below freezing, odi upgraded this investigation to an engineering analysis on February 14, 2008 so that it…
What 2004 Chevrolet Aveo owners say
Engine & cooling all 83 →
Tl contact owns a 2004 Chevrolet Aveo. The contact stated that the service engine warning lamp illuminated several times and then turned off. The contact stated that while traveling approximately 30 MPH, the vehicle was shaking violently and stalled. The contact was able to restart the vehicle and upon pulling over, the contact noticed flames and smoke was emitting from under the hood near the front passenger side. The driver and the front passenger exit the vehicle. The fire was able to be extinguished by the fire department. A police report was filed. The driver and front passenger did not sustain any injuries. The vehicle was destroyed. The manufacturer was not notified of the failure. The contact received notification of NHTSA campaign id number: 14V261000 (exterior lighting). The vehicle was not inspected or diagnosed. The approximate failure mileage was 95,000.
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.
Electrical system all 37 →
Tl contact owns a 2004 Chevrolet Aveo. The contact stated that the service engine warning lamp illuminated several times and then turned off. The contact stated that while traveling approximately 30 MPH, the vehicle was shaking violently and stalled. The contact was able to restart the vehicle and upon pulling over, the contact noticed flames and smoke was emitting from under the hood near the front passenger side. The driver and the front passenger exit the vehicle. The fire was able to be extinguished by the fire department. A police report was filed. The driver and front passenger did not sustain any injuries. The vehicle was destroyed. The manufacturer was not notified of the failure. The contact received notification of NHTSA campaign id number: 14V261000 (exterior lighting). The vehicle was not inspected or diagnosed. The approximate failure mileage was 95,000.
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.
Air bags all 23 →
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.
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.
2004 Chevrolet Aveo engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 1.6L 4-cyl | 5-speed manual | FWD | 23 / 32 / 27 |
| 1.6L 4-cyl | 4-speed automatic | FWD | 23 / 31 / 26 |
EPA ratings. Class: Compact car.
Frequently asked questions
Is the 2004 Chevrolet Aveo a good car?
Based on 206 owner complaints filed with NHTSA, the 2004 Aveo rates average: about as many complaints as a typical year of the Aveo at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Chevrolet Aveo?
The engine & cooling — 83 complaints, 40% of all complaints for this model year, most often about cooling system. Next are the electrical system (37) and air bags (23).
How many recalls does the 2004 Chevrolet Aveo have?
There are 2 recalls for the 2004 Chevrolet Aveo, the most recent from May 19, 2014 (headlights). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Chevrolet Aveo?
The best years by complaints, compared at the same age, are 2010 and 2011. See the full Chevrolet Aveo years comparison.
At what mileage do 2004 Chevrolet Aveo problems happen?
The median mileage reported in complaints is about 60,000 miles; 36% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.