Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
60,474 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chevrolet Aveo engine problems

engine problem

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2004 Chevrolet Aveo Owner Comments (Page 2 of 2)

« Read the previous 20 complaints

problem #11

Mar 252009


  • 112,000 miles


The timing belt broke on my 2004 Chevy Aveo. I understand that this is a problem for alot of people. I contacted my local Chevy dealership and they said I would have to replace the engine.

- Dublin, OH, USA

problem #10

Aug 222009


  • 60,000 miles
2004 Chevy Aveo timing belt broke causing valves to break and many other related parts at 60000 miles. My mechanic said this is common in these cars and he doesn't understand why there has not been a recall. Had I been aware of the problems with the timing belts going at 40-60000 miles it might only have cost me $50 to repair instead of $950. It is my understanding in my research since this occurred by speaking with mechanics ect. All are in agreement they don't understand why there is not something being done on these belts. We were stranded, cost of towing and lengthy and costly repair for what I am finding out to be a common problem with this car and the 2004 year.

- Cloquet, MN, USA

problem #9

Mar 212009


  • 48,000 miles
My 2004 Chevy Aveo has had more problems than you can imagine. I had to replace the timing belt twice, severe engine damage both times. Ocean Chevrolet and GM were absolutely no help. Rotors had to be replaced at 48,000 miles, an evap leak for another $600. Both timing belt repairs were over $2000 each. I have put more into repairing this car than I paid for it. Got runarounds from the dealer and GM and wouldn't recommend a Chevy product to anyone.

- Toms River, NJ, USA

problem #8

Apr 082009


  • 70,000 miles


First of all I learned on the internet that the Chevy Aveo is not a good deal when you are looking for a car. The first time the timing belt broke and spend a lot of money and now the thermostat housing broke because is made of plastic. Like other Aveo owners say, this car have to be recall, because all the problems it have.

- El Paso, TX, USA

problem #7

Dec 172008


  • 53,470 miles
2004 Chevrolet Aveo broke timing belt at 53,470 miles. Always serviced on time. No warning lights. Also, have had electrical problems with car since buying. Dashboard clock resets constantly. Odometer reading fails. This is a dangerous car.

- Malibu, CA, USA

problem #6

Oct 292008


  • 20,100 miles
My car is a 2004, Chevy Aveo, with 23,100 miles. The temperature gage showed the engine to be overheating on my way to work on October 29, 2008. There were no warning lights, only a rambling engine sound and a burning type of smell. The reservoir tank was half empty and there was visible signs of leakage around the thermostat housing. The replacement of the thermostat housing remedied the failure. However, the thermostat housing from the factory is originally encased in plastic housing, but the Chevy dealer retails the part with metal housing. The metal housing indicates Chevy's awareness, yet there is no existence of coverage on the warranty or any issuing of recall of the part.

- Ocala, FL, USA

problem #5

Oct 032008


  • 61,000 miles


We have a 2004 Aveo and no light came on and at 61,000 miles my car just quit running in the middle of the road and had to be towed to the dealership the timing belt had broken and the motor was messed up also. I had to pay over $3,000 to have it repaired cause a belt broke. It messed up half of the motor and had to be replaced. Then a month later the lights on the dash quit working and they told me that they have replaced them alot for these cars and the wire harness is $1,200 dollars and I am paying more for the repairs then I have for the car. The clock light has never worked right since we got the car. So be careful and replace your timing belt early and don't have to pay all that money like we had to. I wish I have never bought the car now.

- Perry, FL, USA

problem #4

Feb 012008


  • miles
2004 Chevrolet Aveo broken timing belt. Consumer states that dealer stated that the problem was under warranty and replaced the valves because they were bent. Consumer would like to know why the timing belt was not replaced. The consumer stated a tsb had been issued for the timing belt problem.

- Shreveport, LA, USA

problem #3

Apr 292008

Aveo 4-cyl

  • 102,000 miles
2004 Chevy Aveo timing belt failure at 47,000 miles, and at 102,000 miles approx. 53,000 miles after the previous failure. Both failures have caused severe engine damage. I have been advised that the most recent failure could result in an entire engine replacement.

- Wareham, MA, USA

problem #2

Jan 102007

Aveo 4WD

  • 55,000 miles
Timing belt went on my Chevy Aveo 2004 in January. @ 55,000 miles and the belt damaged the whole engine. The GMC company refused to repair it. I found out that the Chevy Aveos are having lots of problems.

- Middletown, RI, USA

problem #1

Aug 132005

Aveo 4-cyl

  • Manual transmission
  • 30,000 miles
Intro: Make Chevrolet model kalos 2004 [xxx]. airbag warning indicator was on for several times (more than 10 times). A check was performed on 13 August 2005 and the only repair was to reset the signal from scan tool. The signal remain on continuously being a dangerous situation, service shop refused initially to repair the faulty SRS initiating the corrective actions were delayed for 4 (four) months so on 07 December 2005 were replaced on my vehicle both side airbags module and the SDM (sensing diagnostic module). 2. at 10000 km oil spot appear on top of the engine (engine distribution cover) and even reported to service shop mechanics no action was taken in order to investigate and to correct the failure till 40603 km when the spot extended and contaminate with lubricant timing belt area and following parts had to be replaced: ·hose, breather; ·timing belt ·timing belt expander ·oil seal ring 3. brake, power steering, coolant and clutch fluids and spark plugs were replaced later than normal maintenance schedule, and only after I submitted a written complain to the service shop manager. It supposed to be replaced at 30 000 km and it were replaced at 38070 km. This also it happened with the fuel filter, which had to be replaced at 45000 km, and it was replaced at 49200 km. was reported by the owner that ac is out of service at 49200 km (evap condenser found with a large crack and refrigerant fluid lost completely). According to maintenance schedule at 45000 km service shop had to inspect evap condenser from the conditioning system and the pipelines. Ac periodical maintenance never had been performed to the vehicle as it was stated in the technical specifications. 5.engine oil was not the respecting api specifications so instead 5W 30 synthetic oil was used 10W 40 mineral oil. It took almost 18 months and 40603 km to convince them to use the proper oil for the engine. This thing affected engine life. Updated 07/17/2012

- Constanta, 00, USA

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