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 2005 Chevrolet Aveo owners, lightly cleaned up (personal details are redacted by NHTSA).
GM must not know this this has to do with the electrical wire harness inside of the engine block for the lights. For some reason the power is over writing the fuses and not blowing and causing small engine fires that could get out of control. I caught mine in enough time and put it out. A guy has to do with the right side and the left side in the fuse box being two separate entities of wires which is 7 + 7 equals 14 to control two different sizes. I was just wondering why and GM needs to know what's the sense of having a fuse box if the wires are going to override the fuse. And possibly catch fire or will catch fire it just a matter of an accident waiting to happen. I've been on youtube and found out this is a common thing to happen for Chevy Aveo will there be a 2004 through 2008. …
Tl* the contact owns a 2005 Chevrolet Aveo. The contact stated that the headlights failed. The contact inspected the vehicle and found that the wiring harness connectors shorted due to overheating, which burned and melted the wires. The dealer advised that NHTSA campaign number: 14V261000 (exterior lighting) would only repair the drl module and it would not replace any additional failure caused by the recall. The contact also stated that the engine valve cover gasket was defective and caused the engine fluid to leak. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 80,000.
Tl contact owns a 2005 Chevrolet Aveo. The contact stated that the hazard lights, the tail lights, the marker lights and the instrument panel lights failed. The vehicle was serviced under NHTSA campaign number: 14V261000 (exterior lighting) however, the failures persisted. The vehicle was taken to an independent mechanic, who diagnosed that the s101 splice box burned out and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 80,000.
Car type: 2005 Chevy Aveo problems I have had with this car; 1. Oxygen sensor needed replacement by 41,[redacted] miles 2. At 82,[redacted] mi. Wiring problems in fuse box wires came loose (possibly a fire hazard) burnt the wiring harness. (char marks on the wiring harness) caused the interior (instrument cluster panel) and exterior lights (daytime running lights)(yellow lowbeams that control turn signal) to turn off while driving the vehicle during the night time. Fix cost me $125.00 plus tax 8.25% this isn't the first time I've heard of this happening in fact its on many online forums as happening to several other people. 3. At 92,[redacted] miles. Thermostat housing cracked in the center where the thermostat is located at (thermostat housing is plastic) very cheaply made. No parts houses carry this item. Its a GM part. …
Within the first year of buying my Aveo I had to replace headlights 10x I kept taking the car in to get checked and they said it was fine, then one time they said just needed a better fuse (the changed it) worked for about a year then signal lights kept going out, then tail lights. Thought there was short took car in few times they said nothing wrong. Tired of taking the car in, I am a very busy person. So we have been dealing with this problem for about 6-7 years now the dash lights have completely gone out now and won't come back on, leaving us with 1 headlight, 1 tail light and only occasional rear signals. And always smells light wires burning. In sept of 2014 we received a letter recalling the car for lighting problems and still nothing about getting fixed!!! This is only one of many complaints for this car.
Tl* the contact owns a 2005 Chevrolet Aveo. The contact stated that the interior and exterior lighting failed to illuminate. In addition, the contact noticed that the center console in the instrument panel and the day time running light module was melted. An independent mechanic was made aware of the failure and informed the contact that the vehicle was not safe to drive. The vehicle was not repaired. The manufacturer was notified of the failure. The manufacturer informed the contact that NHTSA campaign id number: 14V261000 (exterior lighting) remedy was being investigated. The approximate failure mileage was 90,000.
I have a 2005 Chevy Aveo sedan that I drove approx. 5 miles and parked in my lot at approx. 11:30 am. When I returned at approx. 3:30 pm the inside of the vehicle had burned under the center of the dash and melted the dash,clock,radio,center console and wiring. In addition it burnt the carpet by the gas pedal,air vents were melted down into the dash,windows were all smoked and the inside has an odor of melted plastic.I feel that if the windows were not all rolled up the complete car would have burned.I feel this is at the fault of the drl module which there is a recall out for.
Interior dash and console lights in-operative as well as the right tail light. Jesus christ, after seeing all of the people complaining about this our beloved no good for nothing governmental agencies should make GM responsible for the cost of repair for this obvious manufacturers or engineering defect. Or at least send out detailed instructions to the owners on how to fix this problem so they can take it to their mechanic of choice to get it fixed. The dealers obviously don't want to do anything about it. And they charge too much any how. Sincerely, george s.
When I went out to start the vehicle I had no dash board lights. Every other light system worked but I could not see the speedometer or the tachometer. All the fuses were intact. I then bought new bulbs for the entire gage cluster and they still are not functioning. I have looked up this problem on multiple forums and this is a very common issue without a solution other than "rigging" this system! This is unacceptable practice to allow this to go on without some sort of recall or replacement part available!
Tl* the contact owns a 2005 Chevrolet Aveo ls. The contact stated while driving approximately 55 MPH, the entire instrument panel failed to illuminate. The contact inspected the vehicle and noticed that the fuel box splice connector was burned. The fuel box and wiring harness would require replacement. The vehicle had not been repaired. The manufacturer was notified of the problem. The approximate failure mileage was 85,000. The VIN was unavailable.
Electrical complaints in other Aveo years
Frequently asked questions
How common are electrical problems on the 2005 Chevrolet Aveo?
NHTSA has 67 complaints about the electrical system of the 2005 Chevrolet Aveo, 29% of the model year's 235 complaints. The component named most often is ignition (2 mentions).
Is there a recall for 2005 Chevrolet Aveo electrical problems?
No. NHTSA lists no electrical system recall for the 2005 Chevrolet Aveo, though it has 1 recall 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 2005 Chevrolet Aveo electrical problems start?
Half of the complaints with a recorded mileage happened before about 85,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 12 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.