Problems owners report
Complaints filed with NHTSA about the 2004 Chevrolet Aveo, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling62
- Electrical system37
- Air bags23
- Engine21
- Power train18
- Seat belts18
- Exterior lighting12
- Fuel system, gasoline9
- Steering9
- Service brakes, hydraulic8
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 20 injuries and 2 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 16 2004 Aveo vehicles were involved in crashes on US public roads in which someone died; 16 people died inside them, and 2 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Chevrolet Aveo failed the safety check 4.83% of the time — 119% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 97,838 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 2 variants: combined 8.9–9.1 L/100 km (about 26 mpg US), CO₂ 205–209 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Aveo · Compact · Regular gasoline | 10.1 | 7.3 | 8.9 |
| Aveo · Compact · Regular gasoline | 10.3 | 7.6 | 9.1 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
6 Transport Canada recalls for the 2004 Chevrolet Aveo.
| 2014185 22 May 2014 | Electrical On certain vehicles, heat generated within the daytime running light (DRL) module could cause the module to melt, potentially resulting in a fire, which may res… |
| 2012274 13 Aug 2012 | Lights And Instruments On certain vehicles, the Daytime Running Lamp (DRL) module may fail, causing one or more of the following conditions: the DRLs may flicker but remain illuminate… |
| 2007275 28 Aug 2007 | Engine On certain vehicles, the engine throttle may stick in the open position due to throttle body icing in temperatures near or below -20 degrees Celsius. If the th… |
| 2006239 28 Sept 2006 | Engine On certain vehicles, the engine throttle may stick in the open position due to throttle body icing in temperatures near or below -20 degrees Celsius. If the th… |
| 2005235 15 Aug 2005 | Other Certain vehicles may experience throttle body icing in conditions where temperatures are near or below -20 degrees Celsius. Vehicle with this conditions could … |
| 2004303 24 Aug 2004 | Seats And Restraints On certain vehicles, the rear outboard shoulder seat belts can contact the seat-back-folding release knob during seat belt use and can twist the seat belt webbi… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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.
ON CERTAIN PASSENGER VEHICLES, THE REAR SAFETY BELT CAN BECOME TWISTED.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Chevrolet told its dealers about the 2004 Chevrolet Aveo: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 11007208 | This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection. |
| 11006621 | Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers. |
| 11006421 | GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return. |
| 11004761 | This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 11004557 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 11002312 | This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information. |
| 11000576 | This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process. |
| 10252735 | This bulletin provides information for electrical ground repairs using new General Motors replacement fasteners with conductive finish. |
| 10252163 | XM Audio Traffic And Travel Link Availability And Operation. |
| 10251890 | This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up. |
| 10250775 | This service bulletin provides service information to technicians on guidelines to replace Oil Cooler, Oil Cooler Lines and Oil Tank if the engine was replaced where large amounts of debris has flowed throughout the oiling system. |
| 10249590 | This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim. |
| 10249579 | This PI bulletin advises the technician on the proper way to install the pistons in an engine. |
| 10249011 | This informational bulletin provides information for dealers/technicians on Headlamp, Tail Lamp, License Lamp or Fog/Driving Lamp Damage. |
| 10248444 | Vehicle Recalls |
| 10247715 | Terminal Test Probe And Replacement Terminal. |
| 10247681 | Information On Requests To Add OnStar Bluetooth Option. |
| 10247552 | This service bulletin provides information on Concerns or Questions Regarding Installation of Dealer Installed Accessories. |
| 10247060 | Terminal Test Probe And Replacement Terminal. |
| 10246952 | Programming And Activation Of Replacement OnStar Modules. |
| 10246951 | Programming And Activation Of Replacement OnStar Modules. |
| 10246631 | Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules |
| 10245951 | Canadian Customers Unable To Place Calls And Turn By Turn Inoperative In The United States. |
| 10245950 | Canadian Customers Unable To Place Calls In The United States |
| 10245395 | This service bulletin provides a vibration analysis worksheet the technician can use in conjunction with the appropriate Vibration Analysis-Road testing procedure when diagnosing vibration concerns. |
NHTSA manufacturer communications (public domain)
NHTSA investigations
STUCK THROTTLE VALVE
STUCK THROTTLE VALVE
NHTSA Office of Defects Investigation