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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 1 of 2)

problem #31

Oct 012015

Aveo 4-cyl

  • miles


2004 Chevrolet Aveo. Consumer writes in regards to warranty notice #14093 issues. The dealer informed the consumer, the warrany had expired. Also, the water pump and timing belt were replaced.

- Miami, FL, USA

problem #30

Sep 012015

Aveo 4-cyl

  • 51,000 miles
2004 Chevrolet Aveo. Consumer writes in regards to vehicle timing belt failure. The consumer stated the vehicle stopped with no warning.

- East Northport, NY, USA

problem #29

May 012013

Aveo 4-cyl

  • 121,000 miles
It's the 3rd time it has happened. It occurred twice with my daughter and her baby in the car, today when I picked my kid up from school; the car cut off while in motion. I have changed throttle position sensor, crank sensor, cooling temperature sensor, 15 amp fuse twice, replaced the head gasket, sealant, egr valve and egr gasket. Cleaned off all oil residue on engine, on head gaskets, on spark plugs. Recently replaced thermostat, radiator, timing belt and have also did a transmission oil change. The car is not working appropriately.

- Bridgeport, CT, USA

problem #28

Nov 062011

Aveo 4-cyl

  • 86,000 miles


The plastic thermostat housing completely snapped while driving only 35 miles per hour. There are mulitple Chevrolet Aveo owners that have a car between the years 04-06 that have had the same problem. Not only is this a safty hazard, but a realitive costly fix.

- Mount Joy, PA, USA

problem #27

Jun 132011

Aveo 4-cyl

  • 65,000 miles
Timing belt failure at highway speed. Almost got into accident. Chevy Aveo only had 65,000 miles.

- Mebane, NC, USA

problem #26

Mar 262011


  • 65,000 miles
I have a 2004 Chevy Aveo that only has 65K miles on it and gets regular oil changes. I went in and had my transmission fluid flushed and was told the car looked great. Drove a few other places, and was on a steep hill, turning around (as I have done many times before), and all of a sudden smoke was pouring out of my engine. I parked immediately. My thermostat housing piece (plastic) had cracked in half and was spewing antifreeze. In the two seconds the car was on, I lost half my anti-freeze and my engine compartment is covered in anti-freeze. Further, the part is hard to find and will take several days for a replacement. This part broke out of the blue, in the middle of routine driving. There's no way to drive it until it's fixed - the car will have to be towed. I hear that the part is now being made in aluminum and that this is a common problem with this car (every 50-70K this piece just inexplicably cracks). I firmly believe that this should be part of a standard recall. Had this piece broke at any other time (such as five minutes prior, when I was on the freeway) there would have been dire consequences. Further, had I attempted to drive the car any further, I could have had an engine fire or several other problems. This has resulted in three days of time and energy to get this repaired (hopefully to be completed tomorrow). This plastic piece is nothing but a safety hazard and I consider myself lucky to have escaped in one piece. I'm yet to find out what kind of damage the anti-freeze will do to my car in the time it takes to get the car into the shop to be fixed up.

- Seattle, WA, USA

problem #25

Feb 282011


  • 48,000 miles


Engine stopped running. At first I was told it was the timing belt but that was not supposed to be changed till around 60,000 miles. The car has only 48,000 miles on it. I went and bought a timing belt and a water pump because I was told that if I changed the belt I may as well change the water pump also. After a good deal of money I was told it was an engine failure because of a "valve ring" had worn away. I need to put a "new" engine in it at considerable cost. I have been laid off for over a year and this has created a hardship for me. I can not afford another car payment and the cost to fix this car, although cheaper than buying another, is still a lot of money for me. Not only is it hard enough to find work it is nearly impossible without a car. I believe this failure should not have happened at 48,000 miles! I am 55 years old and have owned Chevy's all my life. Not happy.

- Macedonia, OH, USA

problem #24

Feb 202011


  • 66,000 miles
My Aveo is supposed to have a warning light to come on when the engine has to be serviced. Apparently, this light did not come on for the warning that there was something wrong with the vehicle that I need to find out about. Driving to me(the vehicle was driven by my child of 28 years with a 3 month old in a rear car seat) to pick me up to take me to work the car just stopped. In the middle of ongoing traffic. Thankfully the car was not hit but the police as well as my brother (whom was on his way to work) were able to get the car to the side of the road. Her father (he was called) showed up with a tow on its way to take it to my mechanic. It was determined that the timing chain/belt went. Because the car was in motion it also caused the bending of 2 pistons. In order to fix it properly this mechanic was not able to do so. I was informed however that all Aveos from this model or year has shown to have the timing belt/chain to malfunction between the mileage of 40,000- 80,000 miles. So, I am trying to find out if there is a recall on first the warning light not indicating there was something wrong and second, the timing chain/belt malfunctioning repeatedly between the miles of 40,000-80,000 miles. I love my Aveo because it is the perfect size, excellent on gas and being a 2004 model there is only about 66,000 miles or so on it. I am truly missing my Aveo and would appreciate it if someone can help me get it back to normal so I can take it home. I have to say that this is my first real car and I would rate it in the top ten vehicles to purchase for its total economical qualities. So, please let me know at your earliest convenience.

- Plymouth Meeting, PA, USA

problem #23

Jan 242011

Aveo 4-cyl

  • 58,000 miles
Chevy 2004 avero timing belt broke which also damage engine had to replace valves which cost over $1100. This incident happen when my wife was coming from therapy on a highway (bqe), in brooklyn when out of no-where with no warning signs, the car just stop, which could have cause a unthinkable events of accidents. Thank to my higher power, that no one was hurt or even worse, fatally injured. I had the engine re-built, hopefully this would never happen again, because I will always have the timing belt inspected ever time I change the oil to avoid any failure or unwanted injuries or death due to GM lack of not recalling this vechicle because my 2004 avero only had 58,000 moles only, when the car manual indicates that it should be replace every 60,000 miles.

- Jamaica, NY, USA

problem #22

Dec 282010

Aveo 4-cyl

  • 92,941 miles
Was sitting at a stop light when the engine all of the sudden quit. Listening to it while trying to restart the engine, my first though was timing belt. After getting the vehicle home and inspected, the timing belt was tight but not turning anything, upon further examination it was discovered that 14 of 16 valves are bent although the crank shaft turn the timing belt is not. This is a problem that GM knows about with the 2004 Chevrolet Aveo and will not stand behind their product when they know they have a problem. #1 no clearance between piston and valves. #2 faulty timing belt.

- Indianapolis, IN, USA

problem #21

Dec 052010


  • 80,000 miles


My daughter's first car purchase...what a disappointment. Bought the 2004 Chevy Aveo used with 80,000 miles on it on a Saturday. It broke down Sunday. Timing belt broke and caused severe damage to the it needs to be replaced. Always do your research...a quick search while watching the car get towed showed that this is a huge, wide-spread problem that GM has decided to do nothing about. Dealership working with us to resolve the problem with a swap in vehicles.

- Nashua, NH, USA

problem #20

Oct 082010


  • 55,000 miles
I was driving home on the highway in my 2004 Chevy Aveo. Suddenly I noticed that I was unable to accelerate and that I had lost pressure in my brakes. I had to pull over to the side of the road and put on my hazard lights. It was very busy traffic and I narrowly avoided an accident. My engine would no longer start. After having my car towed to my mechanic I discovered my timing belt/chain had broken and damaged my engine and that it will have to be replaced. Car only has 55,000 miles.

- Decatur, IL, USA

problem #19

Jul 052010

Aveo 4-cyl

  • 59,000 miles
The contact owns a 2004 Chevrolet Aveo. While the contact was driving 55 mph in rainy weather conditions, the vehicle began to jerk and the engine stalled without warning. The engine would not restart. The vehicle coasted to the side of the road and then towed to a nearby independent mechanic. The failure was attributed to the timing belt. The vehicle was not repaired. The failure mileage was 59,000. Updated 01/24/11 the consumer was quoted a price of $2500, but informed it may break again. Updated 03/22/11

- Milltown, WI, USA

problem #18

Sep 272010

(reported on)


  • 59,000 miles
2004 Chevrolet Aveo. Consumer states the vehicle stopped in the middle of traffic on the highway the consumer stated the timing belt failed.

- Milltown, WI, USA

problem #17

Jul 132010


  • 64,675 miles
Engine stops running.

- Highland, CA, USA

problem #16

May 212010


  • 41,000 miles
2004 Chevy Aveo with 41,000 miles. Timing belt broke, bending all of the valves in the engine. No prior problems with this car. Replaced the timing belt, will now have to replace the head on the engine.

- Wilmington, NC, USA

problem #15

May 242010


  • 92,000 miles
I was driving at 65 mph and the car stalled and had to cross two lanes of traffic to get to the side of the road. The timing belt has been the source of my problem, it stripped out the teeth on the belt. Why would Chevy use a timing belt when all of its other cars use chains, why not modify the engine they bought from Daewoo and put a chain on it.

- Fort Wayne, IN, USA

problem #14

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 #13

Dec 082009

Aveo 4-cyl

  • Automatic transmission
  • 46,500 miles
The contact owns a 2004 Chevrolet Aveo. While driving between 40-45 on an incline she heard a loud knocking noise in the engine compartment. Next the engine stalled. The vehicle has not been inspected for the malfunction at this time. The failure and current mileages were 46,500. Updated 1/11/09 the timing belt failed and locked up the engine. Updated 01/13/10.

- Billings, MO, USA

problem #12

Jun 192009


  • 54,000 miles
The contact owns a 2004 Chevrolet Aveo. The engine warning light would intermittently illuminate on the instrument control panel. Also the vehicle would shimmy while driving. The vehicle was taken to the dealer and a tune-up was performed. After the repair the failure resurfaced so the vehicle was taken back to the dealer. She purchased a fuel cap. The repair did not remedy the failure because the vehicle exhibited a no-start condition. A mechanic stated that the timing chain fractured. No repairs were made. The current mileage was approximately 63,000. The failure mileage was approximately 54,000.

- Westmont, IL, USA

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