Does the 2004 Chevrolet Aveo have any recalls?

Yes. NHTSA lists 2 recalls for the 2004 Chevrolet Aveo, the most recent reported on May 19, 2014 (Exterior lighting: headlights). Check a specific car by its VIN at nhtsa.gov/recalls.

What are the most common problems with the 2004 Chevrolet Aveo?

Owners have filed 206 complaints with NHTSA. The most frequently reported area is engine and engine cooling (62 complaints), followed by electrical system (37).

How many 2004 Chevrolet Aveo complaints mention a crash or fire?

23 of 206 complaints report a crash and 9 a fire; 20 injuries were reported in total. Complaints are unverified reports from owners.

2004 Chevrolet Aveo recalls and problems

2 recalls and 206 owner complaints on file with NHTSA for the 2004 Chevrolet Aveo.

recalls

206

owner complaints

complaints mentioning a crash

mentioning a fire

Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.

2004 Chevrolet Aveo recalls

Exterior lighting: headlights

NHTSA campaign 14V261000 · reported May 19, 2014 · General Motors LLC · 218,000 vehicles potentially affected

The problem: 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.
The risk: If the DRL module melts due to the heat generation, it could cause a vehicle fire.
The fix: 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.

Seat belts: rear/other

NHTSA campaign 04V407000 · reported August 17, 2004 · GENERAL MOTORS CORP. · 32,301 vehicles potentially affected

The problem: On certain passenger vehicles, the rear safety belt can become twisted.
The risk: 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.
The fix: 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.

Most reported problems

Areas named in owner complaints to NHTSA. One complaint can name several areas.

Engine and engine cooling62
Electrical system37
Air bags23
Engine21
Power train18
Seat belts18
Exterior lighting12
Fuel system, gasoline9
Steering9
Service brakes, hydraulic8

What owners report

Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.

Jul 24, 2019 · Air bags · 208,000 miles · crash reported
TAKATA RECALL. ON OCTOBER 13TH 2018 I WAS IN A HORRIFIC ACCIDENT WHILE ON THE HIGHWAY WAS AN SINGLE CAR ACCIDENT MY TIRE SHREDDED BUT STILL MAINTAINED AIR AND MY AIRBAGS DIDN'T DEPLOY ON EITHER SIDE AND I GOT A BROKEN NOSE AND A FEW FACIAL FRACTURES. NOW I HAVE SEVERE HEADACHES EVERYDAY SINCE THEN.

Dec 1, 2018 · Visibility/wiper · 60,000 miles
WHAT'S WITH AVEO'S PASSENGER SIDE WINDSHIELD WIPER? IT SKIDS OFF THE WINDOW AND WIPES THE TRIM. WHEN I FIRST BOUGHT MY CAR I THOUGHT SOMEONE MADE A MISTAKE AND PUT ON THE WRONG SIZE. WHEN THEY NEEDED REPLACED, I REPLACED THE WHOLE ARM WITH A SET MATCHING MAKER SPECIFICATIONS. AND MADE NO IMPROVEMENT AT ALL. THE TIP OF…

Sep 28, 2018 · Engine · 116,000 miles · fire reported
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 THE VEHICLE WAS NOT…

Jul 18, 2018 · Electrical system · 110,468 miles
IGNITION SWITCH IS OVERHEATING. THE LONGER THE CAR IS DRIVEN (10-15 MILES) THE HOTTER IT IS BECOMING. IT HEATS UP SO MUCH THAT THE IGNITION KEY BECOMES QUITE HOT AS WELL...BUT THE SWITCH ITSELF IS EVEN HOTTER. I FEAR THERE WILL BE AN ELECTRICAL FIRE STARTING SOON, AND HAVE ALREADY DECIDED TO STOP AT INTERVALS TO TURN…

Jul 26, 2017 · Electrical system · 91,000 miles
TL* THE CONTACT OWNS A 2004 CHEVROLET AVEO. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE WOULD SUDDENLY SHUT OFF WHEN PRESSING THE ACCELERATOR PEDAL. THE VEHICLE WAS TAKEN TO HALEY AUTOMOTIVE GROUP DEALER LOCATED IN RICHMOND, VA BUT THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED. THE…

Aveo model years compared

Year	Recalls	Complaints	Crashes	Fires
2004	2	206	23	9
2005	1	235	19	17
2006	1	189	13	16
2007	2	216	25	13

Across all years, the 2005 Aveo has the most complaints (235). All Chevrolet Aveo years →

Questions

Does the 2004 Chevrolet Aveo have any recalls?: Yes. NHTSA lists 2 recalls for the 2004 Chevrolet Aveo, the most recent reported on May 19, 2014 (Exterior lighting: headlights). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2004 Chevrolet Aveo?: Owners have filed 206 complaints with NHTSA. The most frequently reported area is engine and engine cooling (62 complaints), followed by electrical system (37).
How many 2004 Chevrolet Aveo complaints mention a crash or fire?: 23 of 206 complaints report a crash and 9 a fire; 20 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received July 24, 2019.