NHTSA vehicle safety data

2004 Chevrolet Aveo Recalls, Ratings & Complaints

The 2004 Chevrolet Aveo has 2 NHTSA recall campaigns and 206 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Chevrolet dealer.

NHTSA recall and complaint data for the 2004 Chevrolet Aveo, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.

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2004 Chevrolet Aveo owner complaints

Owners have filed 206 complaints with NHTSA about the 2004 Chevrolet Aveo, describing incidents dated March 9, 2004 to October 13, 2018.

Most-cited components

Engine 83 complaints
Electrical System 37 complaints
Air Bags 23 complaints
Power Train 18 complaints
Seat Belts 18 complaints
Exterior Lighting 12 complaints

Of the 206 complaints on file, 23 report a crash and 9 a fire; across all 206 complaints, owners report 20 injuries and 2 deaths (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11234617 · Filed July 24, 2019
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.
ODI #11155289 · Filed December 1, 2018
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…
ODI #11132146 · Filed September 28, 2018
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…

Read all 206 complaints

Owner-reported

2004 Chevrolet Aveo mileage at failure

158 of the 206 complaints on file for the 2004 Chevrolet Aveo give the vehicle's mileage when the problem happened.

Mileage at failure by component, from owners' complaints to NHTSA
Component	Median	Middle half	Based on
Engine	Median 65,000 miles	Middle half 55,000–85,000 miles	Based on 75 complaints

A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.

Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.

These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.

Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Chevrolet Aveo in 2 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Engineering Analysis EA08-005: STUCK THROTTLE VALVE
Closed October 14, 2008
Preliminary Evaluation PE07-051: STUCK THROTTLE VALVE
Closed February 14, 2008

Open and recently closed NHTSA defect investigations

Daytime Running Light Module Overheating

NHTSA #14V261000 · Exterior Lighting — Headlights · NHTSA notice

Reported May 19, 2014 · General Motors LLC

Potentially affected: 218,000 vehicles

Repair completion: 28.62% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign 14093, 14236 · Owners notified February 6, 2015 · Vehicles built September 27, 2003 – March 25, 2004 (per NHTSA)

Defect description

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.

Safety consequence

If the DRL module melts due to the heat generation, it could cause a vehicle fire.

Manufacturer 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. The recall began on February 6, 2015. Owners may contact General Motors customer service at 1-800-222-1020 (Chevrolet). General Motors recall number for this campaign is 14236.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

GM/REAR SAFETY BELT TWISTED

NHTSA #04V407000 · Seat Belts — Rear/Other · NHTSA notice

Reported August 17, 2004 · GENERAL MOTORS CORP.

Potentially affected: 32,301 vehicles

Manufacturer campaign 04069 · Owners notified October 11, 2004 · Vehicles built September 1, 2003 – July 31, 2004 (per NHTSA)

Defect description

ON CERTAIN PASSENGER VEHICLES, THE REAR SAFETY BELT CAN BECOME TWISTED.

Safety consequence

IF THIS OCCURS THE SAFETY BELT RETRACTOR MAY LOCK IN POSITION SO THAT THE BELT CANNOT BE USED. IN THE EVENT OF A VEHICLE CRASH, PERSONAL INJURY TO THE SEAT OCCUPANT COULD OCCUR.

Manufacturer 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. VEHICLE OWNERS LOCATED IN GUAM SHOULD CONTACT GM CUSTOMER ASSISTANCE AT 1-671-648-8453.

Notes

GM RECALL NO.04069.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

2004 Chevrolet Aveo 4-DR.

—

out of 5

Overall Safety Rating

Not Rated

Frontal Crash

Not Rated

Driver: 5, Passenger: 5

Side Crash

Not Rated

Driver: 3, Passenger: 3

Side Pole

Not Rated

Rollover

Not Rated

Safety Technology

2 investigations

2004 Chevrolet Aveo 5-DR. Hatchback

—

out of 5

Overall Safety Rating

Not Rated

Frontal Crash

Not Rated

Driver: 5, Passenger: 5

Side Crash

Not Rated

Driver: Not Rated, Passenger: Not Rated

Side Pole

Not Rated

Rollover

Not Rated

Safety Technology

2 investigations

206 owner complaints have been filed with NHTSA for the 2004 Chevrolet Aveo.

Air Bags; Wheels

ODI #11234617

Crash 1 injury

Incident: October 13, 2018 · Filed: July 24, 2019

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.

Visibility/Wiper

ODI #11155289

Incident: September 12, 2007 · Filed: December 1, 2018

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...

Engine

ODI #11132146

Fire

Incident: September 25, 2018 · Filed: September 28, 2018

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

ODI #11112274

Incident: June 1, 2018 · Filed: July 18, 2018

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.

Electrical System

ODI #11010734

Incident: July 20, 2017 · Filed: July 26, 2017

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

Vehicle Speed Control; Engine

ODI #10935088

Incident: December 13, 2016 · Filed: December 13, 2016

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.

Air Bags

ODI #10883634

Incident: July 1, 2016 · Filed: July 8, 2016

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

Tires

ODI #10873854

Incident: June 9, 2016 · Filed: June 13, 2016

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.

Electrical System

ODI #10873192

Incident: January 7, 2016 · Filed: June 8, 2016

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.

Power Train; Engine

ODI #10850538

Incident: March 11, 2015 · Filed: March 19, 2016

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 AVEOS. ALL OF THE TIMING BELTS FAILED BELOW 100,000 MILES. THERE ARE SIMILAR COMPLAINTS FOR THE 2005 CHEVY AVEO. WHY WASN'T I NOTIFIED ABOUT THIS PROBLEM SO I WOULD NOT LOSE MY SHORTS ON MY VEHICLE. I COULD HAVE BEEN KILLED. THE EVENT WAS TERRIBLY FRIGHTENING. I SUFFER FROM HEART FAILURE. MY NEW CAR PAYMENT IS VERY HARD TO DEAL WITH ON A FIXED INCOME. I TOOK EXCELLENT CARE OF THE CAR. I SHOULD HAVE BEEN CONTACTED ABOUT SUCH DANGEROUS CONDITION. I WOULD LIKE SOME ANSWERS.

Other Chevrolet Aveo model years

Check your 2004 Chevrolet Aveo VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Chevrolet Aveo at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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