VehicleVerdict

2004 Chevrolet Aveo problems

Verdict · NHTSA data

A typical year for this model

The 2004 Chevrolet Aveo sits mid-pack among Aveo years: 271 NHTSA complaints against a model median of roughly 271, with 2 recalls and 2 closed investigations. Reports tied to this model year include 3 deaths and 24 injuries, per the complaint records themselves.

Engine leads the complaint categories with 85 reports (31% of the total).

271

NHTSA complaints

2

Recalls

2

Investigations

27

Crash-involved

13

Fires reported

24

Injuries

3

Deaths

—

NCAP overall

How does 2004 compare to other Aveo years?

Aveo NHTSA complaints by model year, 2004 highlighted323 complaints2004: 271 complaints2005: 323 complaints2006: 280 complaints2007: 307 complaints2008: 251 complaints2009: 278 complaints2010: 105 complaints2011: 112 complaints2012: 3 complaints
Aveo NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all Aveo years to avoid →

What are the most common 2004 Chevrolet Aveo problems?

ComponentComplaintsShare
Engine8531%
Electrical System3914%
Airbags238%
Seat Belts207%
Transmission207%
Lighting166%
Fuel System114%
Brakes104%
Steering93%
Speed Control62%
Other62%
Body & Structure62%
Tires & Wheels62%
Visibility & Wipers52%
Suspension52%
Latches & Locks21%
Climate Control (A/C & Heat)10%
Seats10%

Does the 2004 Chevrolet Aveo have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

14V261000LightingMay 19, 2014 · 218,000 units

Defect

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.

Consequence

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

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.

04V407000Seat BeltsAugust 17, 2004 · 32,301 units

Defect

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

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.

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“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…”

Complaint filed with NHTSA · Engine · September 25, 2018 · fire

“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*CN UPDATED 10/23/2015 *JS”

Complaint filed with NHTSA · Electrical System · October 14, 2014 · fire

“TL*THE CONTACT OWNED A 2004 CHEVROLET AVEO. WHILE DRIVING APPROXIMATELY 35 MPH, THE VEHICLE CRASHED INTO THREE DEER. THE AIR BAGS DID NOT DEPLOY. THE VEHICLE WAS DESTROYED AND THE CONTACT WAS INJURED. THE CONTACT WAS TRANSPORTED TO THE HOSPITAL AND A POLICE REPORT WAS FILED. THE CURRENT AND FAILURE…”

Complaint filed with NHTSA · Airbags · April 19, 2010 · crash

“THE CONSUMER WAS INVOLVED IN A VEHICLE ACCIDENT WHEREBY THE SEAT BELTS DID NOT WORK. THE DRIVER SEAT BELT BROKE AND A TODDLER WAS THROWN TO THE FRONT SEAT. AFTER COMPLAINING TO THE MANUFACTURER ABOUT THE FAILURE, GM STILL DID NOT COOPERATE. THE CONSUMER JUST RECEIVED A RECALL ON THE SEAT BELT.…”

Complaint filed with NHTSA · Seat Belts · August 12, 2004 · crash

“TL* THE CONTACT OWNS A 2004 CHEVROLET AVEO. THE VEHICLE WAS PARKED AND SHUT OFF WHEN A CHILD WAS ABLE TO SHIFT THE VEHICLE INTO GEAR WITHOUT APPLYING THE BRAKE. THE VEHICLE BEGAN TO ROLL FORWARD UNTIL CRASHING. A POLICE REPORT WAS NOT FILED AND THERE WERE NO INJURIES. THE VEHICLE WAS NOT TAKEN TO…”

Complaint filed with NHTSA · Transmission · April 6, 2011 · crash

2004 Chevrolet Aveo — common questions

Is the 2004 Chevrolet Aveo reliable?

It is close to typical for the Aveo: 271 NHTSA complaints, 2 recalls, and 2 investigations on file.

What are the most common 2004 Aveo problems?

According to NHTSA complaint data, the leading problem areas are engine (85 complaints), electrical system (39 complaints), airbags (23 complaints).

Does the 2004 Chevrolet Aveo have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Chevrolet Aveo. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Chevrolet Aveo under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.