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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
55,585 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

problem #13

Apr 212010


  • 81,000 miles


On my daughters 2004 Chevy Aveo I had the timing belt, water pump, and T'belt tensioner replaced at 59826 miles, per manufactures recommendation. About 20000 miles later the idler pulley broke, destroyed engine. GM has not recommended replacing this part per their maintenance schedule, why not?

- Hannibal, MO, USA

problem #12

Apr 052010


  • 45,000 miles
5 months ago, we replaced our 2004 Chevy Aveo's engine due to timing belt failure and had a new one put in. Today (2 weeks after) our car broke down again due to timing belt failure we are finding out we are needing to replace the engine again!

- Columbus, OH, USA

problem #11

Mar 302010

Aveo 4-cyl

  • 95,000 miles
Engine destroyed by timing chain failure. Timing chain failure resulted in damaged pistons and valves. Vehicle had 95,000 miles on it.

- Buffalo, NY, USA

problem #10

Mar 262010

Aveo 4-cyl

  • 55,000 miles


The timing belt on my 2004 Chevy Aveo broke at 55,000 miles. GM recommends that the timing belt on Aveos be replaced at 60,000 miles. There have been numerous reports of Aveo timing belts breaking between 50,000 to 56,000 miles; however, GM has not posted a warning on their website, nor have dealerships been informed. A closer inspection of my car revealed that the idler pulley, which is made of plastic, melted and molded itself to the engine block, which is what caused the belt to break.

- South Elgin, IL, USA

problem #9

Mar 182010


  • 97,000 miles
Vehicle towed to dealership Oct. 2009 no compression repair clean carbon from engine. Had timing belt replaced at this time as preventative maint. Engine failure on highway March 2010. Idler pulley broke bent all valves and broke 1 need to replace engine. Have read many complaints on line same issue with 04 & 05 Chevy Aveo

- Pocomoke, MD, USA

problem #8

Feb 032010


  • 53,000 miles
While on my way home, I noticed that my vehicle started smoking from the hood and without warning the "check" dash lights came on. I noticed that my car started slowing down and I coasted it to the side of the road. At this point my vehicle cut off and wouldn't start. Once, my vehicle was transported home, I had my mechanic to come out and inspect my vehicle. My mechanic looked under my hood and saw that my vehicle had lost alot of antifreeze/coolant. He looked to see what cause this and realized that the thermostat housing unit had busted-actually it was split in half. My mechanic also stated that the busted thermostat housing had caused the leakage of the antifreeze/coolant. My mechanic informed me that the thermostat housing had to be replaced. After having the thermostat housing replaced, my mechanic tried to start the car, but it wouldn't turn over. I had my vehicle jumped, and even the battery inspected but it wouldn't start. In addition, the starter, timing belt were inspected as well and were in good condition. Please be advised that I only have 53,000 miles on my vehicle. My mechanic did a thorough check of my vehicle and realized that some water had leaked into my oil and that antifreeze/coolant had spilled into an engine valve. From my own research, I've found that Chevy has had numerous problems from the 2004 Chevy Aveos-thermostat housing units from other customers. In addition, originally the thermostat housing was plastic, but Chevy changed it to an aluminum one because the "plastic thermostat housing" that originally came with the vehicle was extremely faulty. It is very dishonest and a shame that GM/Chevy never notified me that I needed to bring my 2004 Chevy Aveo in to get the plastic thermostat housing replaced with the new aluminum one. I bought this vehicle brand new in 2005. It was Chevy's responsibility to notify me of this situation. Also, from what I've gathered, the plastic thermostat housing was unsafe.

- Chesapeake, VA, USA

problem #7

Feb 042010


  • 59,000 miles


Timing belt failed, causing engine to fail while in traffic. Engine was destroyed by the timing belt failure.

- Valdez, AK, USA

problem #6

Jan 142010


  • miles
I am driving my 2004 Chevy Aveo at 35 miles an hour, all of a sudden it died. I have 54,000 miles on it. I had it towed to a mechanic and they said that the timing belt broke and now I need to replace the engine. In my manual it says that timing belts need to be checked at 60,000 miles. I was told by GM that even the that is the case I am out of my warranty so tough luck. I have found about 300 complaints about the same thing happening while searching online. I don't know if there is anything you can do about this but I am trying anything I can to get my car fixed.

- Fairborn, OH, USA

problem #5

May 202009


  • 99,999 miles
The contact owns a 2004 Chevrolet Aveo. The vehicle was purchased in November 2007 with 61,000 miles. While driving approximately 45 mph, the vehicle stalled. The vehicle was towed a dealer and an independent mechanic who stated that the timing belt failed and also caused the engine rods to break. The repairs were at the owner's expense. Transmission computer also failed on four separate occasions. The VIN was not available. The failure mileage was 99,999 and the current was 103,000.

- Columbus, OH, USA

problem #4

Aug 152009


  • 13,400 miles
The contact owns a 2004 Chevrolet Aveo. While driving various speeds, the vehicle shut off without warning. The dealer was unable to duplicate the failure. The current and failure mileages were 13,400.

- San Francisco, CA, USA

problem #3

Sep 122007

Aveo 4-cyl

  • Automatic transmission
  • 49,000 miles


The contact owns a 2004 Chevrolet Aveo. The vehicle started for 30 seconds and then shut off. The vehicle failed to restart. The repair shop stated that the timing belt failed and caused the valves to bend. The current and failure mileages were 49,000.

- Manchester, NH, USA

problem #2

Apr 212007

Aveo 4-cyl

  • Automatic transmission
  • 70,000 miles
Timing belt failed at 70,000 miles causing severe engine damage. Timing belt failure is apparently an issue with the Aveo as GM issued a service bulletin on this in Oct 2006. Based on internet search of Aveo problems, Chevy is having problems with the Aveo's timing belt failing even before the recommended service date.

- Pittsburgh, PA, USA

problem #1

Oct 212004

Aveo 4-cyl

  • Manual transmission
  • 5,200 miles
Fuel injector stuck open making a loud tick. GM told me it was a lifter engine is DOHC.

- Warren, MI, USA

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