The 2004 Chevrolet Aveo has 2 NHTSA recall campaigns affecting an estimated 250,301 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 271 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
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.
Consequence
If the DRL module melts due to the heat generation, it could cause a vehicle fire.
Remedy
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…
SEAT BELTS04V4070002004-08-1732,301 affected
Defect
ON CERTAIN PASSENGER VEHICLES, THE REAR SAFETY BELT CAN BECOME TWISTED.
Consequence
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.
Remedy
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.
Complaints by component
ENGINE AND ENGINE COOLING
31
ELECTRICAL SYSTEM
27
1crashes5fires1injuries
ENGINE
21
1crashes4fires
AIR BAGS
15
9crashes7injuries
ENGINE AND ENGINE COOLING:COOLING SYSTEM
14
1fires
ENGINE AND ENGINE COOLING:ENGINE
13
EXTERIOR LIGHTING
10
1crashes2fires
POWER TRAIN
9
1crashes
SEAT BELTS:REAR/OTHER
9
POWER TRAIN:AUTOMATIC TRANSMISSION
8
1crashes
Total complaints271
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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.”
“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.”
“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…”
“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…”
“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…”
“While backing up my vehicle I shifted the transmission from drive to reverse. The engine immediately accelerated to approximately 500 rpm. I immediately put my foot on the break, shifted to neutral, and turn the ignition to off. I was able to immediately restart to vehicle with no problem. This…”
“While backing up my vehicle I shifted the transmission from drive to reverse. The engine immediately accelerated to approximately 500 rpm. I immediately put my foot on the break, shifted to neutral, and turn the ignition to off. I was able to immediately restart to vehicle with no problem. This…”
“Tl* the contact owns a 2004 chevrolet aveo. The contact stated that the air bag warning indicator remained illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 140,390. Updated 09/22/16*lj *js”
Defect investigations
InvestigationEA08005 Opened 2008-02-14 · closed 2008-10-14
STUCK THROTTLE VALVE
TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 29 NON-DUPLICATIVE COMPLAINTS/FIELD REPORTS AND 52 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT AFFECTING 69 UNIQUE SUBJECT VEHICLES.BECAUSE THE ALLEGED DEFECT CONDITION IS MOST LIKELY TO OCCUR DURING WINTER MONTHS WHEN AMBIENT TEMPERATURES ARE BELOW…
InvestigationEA08005 Opened 2008-02-14 · closed 2008-10-14
STUCK THROTTLE VALVE
TO DATE, THE OFFICE OF DEFECTS INVESTIGATION (ODI) IS AWARE OF 29 NON-DUPLICATIVE COMPLAINTS/FIELD REPORTS AND 52 WARRANTY CLAIMS RELATED TO THE ALLEGED DEFECT AFFECTING 69 UNIQUE SUBJECT VEHICLES.BECAUSE THE ALLEGED DEFECT CONDITION IS MOST LIKELY TO OCCUR DURING WINTER MONTHS WHEN AMBIENT TEMPERATURES ARE BELOW…
InvestigationPE07051 Opened 2007-10-19 · closed 2008-02-14
STUCK THROTTLE VALVE
ON OCTOBER 19, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE INCIDENTS DUE TO ICE FORMATION WITHIN THE ENGINE AIR INTAKE TRACT IN CERTAIN MODEL YEAR (MY) 2004-2005 CHEVROLET AVEO VEHICLES MANUFACTURED FOR SALE OR LEASE IN THE UNITED STATES.THIS…
InvestigationPE07051 Opened 2007-10-19 · closed 2008-02-14
STUCK THROTTLE VALVE
ON OCTOBER 19, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE INCIDENTS DUE TO ICE FORMATION WITHIN THE ENGINE AIR INTAKE TRACT IN CERTAIN MODEL YEAR (MY) 2004-2005 CHEVROLET AVEO VEHICLES MANUFACTURED FOR SALE OR LEASE IN THE UNITED STATES.THIS…
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Chevrolet Aveo as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.