fairly significant
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
13,000 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 exhaust system problems

exhaust system problem

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2004 Chevrolet Aveo Owner Comments

problem #3

Jun 202007

Aveo 4-cyl

  • Automatic transmission
  • 34,000 miles


No crash, no injuries; incident began with regular maintenance of vehicle after I purchased the Aveo used; my fuel economy continued to decrease from about 33 to 34mpg down below 30mpg even though I was continuing to drive the same way every week. Economy was about 33-34mpg at 26K miles and eventually at 28-29 mpg by 34K miles. After changing fuels, adding injector cleaner, checking tire pressure weekly, checking spark plug wires with no obvious damage or abuse to any component, I finally pried open the black air cleaner box by breaking two of the rusted bolt/flanges on the cleaner. The air cleaner was almost completely plugged. I changed the filter and the fuel mileage was back to 35 to 37 mpg. But unfortunately I had to break two bolt/flanges on the cleaner box to get the cleaner open. I noticed one other flange was already broken. I believe that the original owner never changed the air filter. The filter is inaccessible once the bolts are rusted to the nuts. I asked the dealer about this and found I cannot get reimbursed since I damaged the cleaner. I believe that the dealer would not be able to access the filter either. I did notice that the bolts are steel/iron because of the rust color and the flange has a captured nut made of brass with bluish-green rust. The use of two dissimilar metals under the hood of a car where salt and corrosion are highly likely is extremely dissatisfied to a consumer. I have to pay money out of my pocket for a filter box replacement when the filter box should have never been engineered this way. This seems like this issue should be an emissions issue since my fuel economy was severely affected. Please let me know what my options are.

- Davisburg, MI, USA

problem #2

Aug 102007

Aveo 4-cyl

  • Automatic transmission
  • miles
During a recent oil change maintenance procedure I was informed that the service to my air filter was not possible due to the inability to remove the screws/bolts/fasteners that could not be removed.

- Buffalo, NY, USA

problem #1

Jan 102005

Aveo 4-cyl

  • Automatic transmission
  • 5,000 miles
When starting my 2004 Chevrolet Aveo after it warmed up and sat for roughly 5 minutes it will not always start on first turn of key. Occasionally, rough idling on cold start, coolant smell coming from heating vents only when heat was on, a light blue/green residue/powder has been found on all four vents. At 5600 miles coolant level at 1/2 factory level, and traces of coolant were found on 2 of 4 spark plugs by independent mechanic. Coolant fumes are noxious, and it seemed I had a cold I couldn't get rid of all winter. As of 4/13/2005 the vehicle has been to 2 different Chevrolet dealerships 4 times, . 3 times at dealership of purchase, and 1 time at another dealership. Nothing could be duplicated, and car was checked out. Everything was okay this time. Dealerships checked spark plugs, did pressure tests, and scanned for codes. At this point the second dealership was looking into the residue/powder.

- Redding, CT, USA

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