Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
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).
The contact owns a 2005 Chevrolet Aveo. The contact stated while driving 45 MPH and making a stop, the vehicle inadvertently lost motive power. The contact was unable to restart the vehicle after several attempts. The contact was able to push the vehicle to the nearby gas station with assistance. The contact refilled the coolant reservoir and was able to restart the vehicle. The vehicle was taken to the independent mechanic who diagnosed that the vehicle had overheated, and the valve cover gasket needed to be replaced. The vehicle was not repaired however, the valve cover gasket was sealed. The dealer and the manufacturer were not notified of the failure. The vehicle was not repaired. The approximate failure mileage was 140,000.
Timing belt/chain broke. Car is below the 60,000 mile mark for scheduled replacement as stated from manufacturer. Car broke down suddenly in the middle of the road creating a hazard to the driver and others.
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. …
The mileage and speed are approximate. I was backing out of my ice and snow covered driveway in February 2015. There is a small dip where my driveway meets the street so I accelerated so as not to get my tires stuck in the icy dip. As I was backing my car into the street, and my car was in the lane of traffic the car shut off. I was unable to restart the car. My neighbor, and another gentleman who stopped to help, pushed my car back into my driveway. I attempted to start the car several times after the incident. The car never again started. I borrowed a vehicle until I had enough money to have the car towed to a mechanic for repairs. A mechanic looked at my vehicle and told me on May 11, 2015 that the car needs a new engine, the price of which is $4,823.00. …
I bought this car brand new and kept up the maintenance religiously! I was horrified to find out that my timing belt went out at 46,000 miles! My manual says to replace timing belt at 60,000 miles. I've read there was a recall issued in 2006, but it didn't go to owners; just service shops...I was never alerted, that was definitely a mistake on GM's part. I feel as though I should be compensated!!!
Tl* the contact owns a 2005 Chevrolet Aveo. While driving 25 MPH, the vehicle stalled without warning. There were no warning indicators illuminated. The vehicle was towed to an independent mechanic who stated that the timing belt, engine, and valves were melted. The vehicle was not repaired. The failure mileage was 53,000.
I drive a 2005 Chevy Aveo, yesterday 10-22-08, while I was driving on the freeway, my engine temp shot up to max. Luckily I was just coming up on my exit so I got to the bottom of the offramp and pulled off to the side. Smoke was pouring out the hood of my car. It turns out the plastic housing thermostat housing cracked in half and all the coolant in my car poured out. While I was sitting on the side of the road waiting for the tow truck my engine continued to get overheated. I replaced my water pump housing myself Chevy has an updated thermostat housing made of metal now, but now I have large amounts of air blowing through my coolant reservoir. My head gasket is blown and possibly the head is warped. I was looking on line for info and it turns out this is a very common problem for many people. …
I am disabled, and in 2005, I purchased a new Chevy Aveo from GM dealer and in 2006 GM sent notice to all dealers that these engines had a defective timing belt and to notify and offer new car buyers a free replacement of the defective part as failure of defective part would likely destroy the engine. I received no notice from GM or my dealer. When my car reached just 49K miles the defective part failed (rubber timing belt) and has caused massive engine damage requiring all new head, valves, and other parts. Dealer refused to even diagnosis the vehicle to avoid documentation of cause and liability and I had at attempt myself and was severely injured. I live on key west and only dealer who sold me the vehicle is miles sales and service. …
I do have complaint that I would like to file. It is regards to 2004-2007 Chevrolet aveos. I had bought my 2005 Aveo brand new from Chevy. It is now my sons car. He was driving the car at 45 MPH came to a stop light and the car just stopped. What had happened is the thermostat housing had blown apart. It is a 2 piece plastic piece of junk. A thermostat housing should never blow apart. In 2008 Chevy starting putting metal ones on the car. One week before this happened my son was traveling with his 2.5 year old daughter in the back roads of pa heading down to visit his grandfather. If this had happened at that time there are long stretches of desolate road and with the mountains many times cell phones do not work. He and my granddaughter could have been in a lot of trouble. I cannot believe that this has not been brought to your attention before, it is all over the web. …
My wife was driving our Chevy Aveo 2005 on a major 4 lane highway during the morning rush hour. She is doing about 60mph in the inner left lane on an icy Tuesday morning commute.then she loses all power and acceleration, every light in the car comes on and she realizes there is a problem. She is mid way up a hill and has to get over. There is an on ramp to her right and more traffic so she had to go into the left berm. By this time she has peaked the top of the hill and is on the flat mesa. There is very little room to move over and she is over as far as possible. State and local traffic enforcement come to her aide and allow her to wait for me and a tow truck to get the vehicle moved. Nearly a dozen cars almost hit them after I arrived on the scene before the determined that it was unsafe for us to wait with the vehicle. They tagged the car and we had it towed. …
NHTSA investigations
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…
Engine complaints in other Aveo years
Frequently asked questions
How common are engine problems on the 2005 Chevrolet Aveo?
NHTSA has 79 complaints about the engine & cooling of the 2005 Chevrolet Aveo, 34% of the model year's 235 complaints. The component named most often is cooling system (16 mentions).
Is there a recall for 2005 Chevrolet Aveo engine problems?
No. NHTSA lists no engine & cooling 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 engine problems start?
Half of the complaints with a recorded mileage happened before about 65,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury to engine & cooling 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.