Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chevrolet Aveo owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
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.
Tl* the contact owns a 2004 Chevrolet Aveo. While starting the vehicle, smoke emitted from the vents and cd player without warning. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 88,000. Updated 5/5/15 updated 10/23/2015
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.
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.
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.
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
We have a 2004 Aveo and no light came on and at 61,000 miles my car just quit running in the middle of the road and had to be towed to the dealership the timing belt had broken and the motor was messed up also. I had to pay over $3,000 to have it repaired cause a belt broke. It messed up half of the motor and had to be replaced. Then a month later the lights on the dash quit working and they told me that they have replaced them alot for these cars and the wire harness is $1,200 dollars and I am paying more for the repairs then I have for the car. The clock light has never worked right since we got the car. So be careful and replace your timing belt early and don't have to pay all that money like we had to. I wish I have never bought the car now.
My 19 year old daughter just arrived at her mothers house, parked the car and came inside. When we started seeing, and smelling smoke. So we went outside to investigate the problem and saw smoke pouring out from under the hood as if there was a fire contained under the hood. So we called 911 and suddenly we heard a loud pop and saw flames on the hood. We proceeded to get a water hose to pour water on the car until finally the firemen arrived. The car still remains in front of her mothers house, if anyone would like to take a look at the car. The firemen deemed it to be a total loss. I would like any information for recalls on this make and model.
Electrical complaints in other Aveo years
Frequently asked questions
How common are electrical problems on the 2004 Chevrolet Aveo?
NHTSA has 37 complaints about the electrical system of the 2004 Chevrolet Aveo, 18% of the model year's 206 complaints. The component named most often is ignition (3 mentions).
Is there a recall for 2004 Chevrolet Aveo electrical problems?
No. NHTSA lists no electrical system recall for the 2004 Chevrolet Aveo, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chevrolet Aveo electrical problems start?
Half of the complaints with a recorded mileage happened before about 72,000 miles, and 13% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 5 fires and 1 injury to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.