Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 3625 | 10018635 | Crank no start after engine repairs - ac pressure sensor and tp sensor connectors may be reverse. *tt | 01/09/2006 | ||
| 050601030 | 09/01/2007 | 050601030D | 10017820 | 1.6l l91 intermittent misfire cold during deceleration or steady state highway driving after cold start with dtc's p0300, p0700, p1781 and/or u0401 set (replace valves and valve stem seals) *tt updated 11/02/07 *nj | 12/02/2005 |
| 3291 | 10013553 | Engine oil pan drain plug replacement information. this includes 2005 pontiac wave tb. *eh | 04/21/2005 | ||
| 050604003 | 01/01/2005 | 050604003A | 10013476 | Intermittent engine misfire hesitation during vehicle warm up. *eh | 04/19/2005 |
| 040137003A | 09/01/2005 | 040137003B | 10012170 | Poor heating performance/insufficient heat during low ambient temperatures. this service bulletin replaces 040137003. *eh | 02/16/2005 |
| 3064 | 10011589 | Service engine soon light engine misfire and p1781 diagnostic trouble code. *eh | 01/27/2005 | ||
| 3160 | 10010544 | Engine block heater information. *eh | 12/01/2004 | ||
| 01744 | 01/01/2004 | 01744A | 10006334 | Information tech 2 anomalies engine data 1.6. *mr *tt | 04/28/2004 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 3538 | 10017011 | Cooling system contains blue coolant from assembly plant. to include 2004 - 2006 chevrolet epica, optr and pontiac wave 2005 - 2006. *sc | 10/20/2005 | ||
| 01887 | 01/01/2004 | 10006516 | Coolant capacities error in owners manual. 2004 chevrolet aveo, 2004 chevrolet optra, and 2004 chevrolet epica.*mr | 05/05/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| SB-10-01-34-001 | 01/01/2010 | 10034371 | Chevrolet: hvac blower motor inoperative, blower motor operates on high speed only (replace blower motor and resister). this condition may be caused by an open resistor. the blower motor operates correctly after replacing the resister, b | 11/08/2010 | |
| 08-06-04-009 | 03/01/2008 | 080604009A | 10024234 | L91 short drive cycle, below freezing temperatures and high humidity may result in throttle body icing condition (diagnosis and report concern first, install pcv valve kit). 2004-2005 chevrolet aveo (u.s. only) with 1.6l 4-cylinder engi | 03/27/2008 |
| 3988 | 3988A | 10021083 | Heli-coil threads pull out of oil pan drain plug opening - replace oil pan. *kb | 03/01/2007 | |
| 06-06-01-021 | 03/01/2008 | 060601021B | 10020843 | Ei06005 - 1.6l l91 timing belt inspection, maintenance, worn, wear. *kb updated 3/31/08. *nj updated 5/15/08. *nj | 01/24/2007 |
| 3936 | 10/03/2006 | 10020573 | Broken timing belt prior to 60,000 miles. bent or broken crank, engine failure, and no start valves under warranty. *kb | 11/17/2006 | |
| 060601001 | 11/01/2006 | 060601001A | 10019475 | Engine oil leak at oil pan drain plug. *tt | 03/15/2006 |
| 3620 | 10018621 | 05-06-01-030 supplement - vin breakpoint revision. *tt | 01/09/2006 | ||
| 05-06-04-065 | 02/01/2008 | 050604065A | 10017762 | Hard start, no start, or rough idle in temperatures near or below -20 degrees c (-4 degrees f). to include 2005 pontiac wave. *tt updated 3/31/08. *nj | 11/29/2005 |
| 3273B | 3273C | 10017225 | Valve lash adjuster tick noise on 1.6l engines - bleed air or inspect adjusters. *tt | 10/28/2005 | |
| 3273 | 10017205 | Engine tick after sitting for prolonged periods. *tt | 10/27/2005 | ||
| 3517 | 10016541 | 05-06-04-003a supplement - ckp learn and updated valve information. *tt | 09/20/2005 | ||
| 01112005 | 01/11/2005 | 10013574 | Replacing the engine's oil pan drain plug sealing washer. *tt | 04/21/2005 | |
| 040604067 | 10/01/2004 | 10011068 | Information on ckp learn procedure after engine control module (ecm) reflash or replacement. 2004-2005 chevrolet epica, optra, vivant and 2005 pontiac wave. *tt | 12/28/2004 | |
| 3166A | 3166B | 10010839 | Service engine soon light due to a p0106, p0300 and/or p2279. to include the new 2005 pontiac wave. *tt | 12/14/2004 | |
| 3065 | 01/01/2004 | 10009597 | Tech 2 engine data parameter anomaly information. *tt | 10/08/2004 | |
| 3064 | 01/01/2004 | 10009596 | Service engine soon light and rough running with diagnostic trouble codes p0700, p1781 and possibly a p0300. *tt | 10/08/2004 | |
| 01653 | 01/01/2004 | 01653A | 10007159 | 1.6 l91 engine diagnostic trouble code p0456.*mr *mj | 06/03/2004 |
| 01870 | 01/01/2004 | 10006592 | Engine tick after sitting for prolonged periods. *mr | 05/06/2004 | |
| 01749 | 01/01/2004 | 10006190 | 1.6 l91 engine- dtc p0135. *mr | 04/26/2004 | |
| 01575 | 01/01/2004 | 10005436 | Diagnostic trouble code (dtc) p1781 diagnostic is not in si yet. poor fuel economy and/or harsh transmission shifts. sit bulletin 1413084. *mn | 02/25/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV) | |||||
| 4294 | 12/01/2007 | 10023757 | Crankcase contamination due to coolant in the engine oil - reseal casting plug. with built before vin breakpoint 8b067818 (july 24, 2007) & 1.6l engine (vin 6 - rpo l91 or lxt). *nj | 01/30/2008 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - CRANKCASE (PCV) | ||||||
| EA08005 | GENERAL MOTORS CORP. | 02/14/2008 | 10/14/2008 | 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 freezing, odi upgraded this investigation to an engineering analysis on february 14, 2008 so that it could continue to monitor the field experience during the 2007/2008 winter season.by letter dated may 22, 2008, general motors corp. (gm) supplemented its previous information request response with field data received by gm through may 1, 2008.according to gm, when moisture freezes in the positive crankcase ventilation (pcv) system and/or the engine air intake tract it is most often observed as a hard to start/no start condition, throttle stuck closed, rough running engine, stalling at idle, or oil leakage.of the 29 complaints related to stuck throttle, odi identified 5 reports that allege unwanted acceleration, 13 reports describe an apparent high-idle condition at start up or when slowing the vehicle to a stop without any allegation of unwanted acceleration or diminished braking performance, and the remaining 11 reports describe ambiguous allegations of stuck throttle without regard to severity or consequence.odi analysis of field incident data shows that the complaint and warranty trends appear to be in decline, with only 1 additional complaint and 6 warranty claims related to the alleged defect received by gm since april 2007. a safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation has been closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will take further action if warranted by the circumstances. | ||||||
| PE07051 | GENERAL MOTORS CORP. | 10/19/2007 | 02/14/2008 | 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 investigation was prompted by a safety recall campaign (05f-069) conducted by general motors corp. (gm) involving substantially similar vehicles manufactured for sale or lease in canada.at that time, gm issued a technical service bulletin (tsb #05-06-04-065) to address the alleged defect condition in u.s. vehicles.gm subsequently revised the canadian recall campaign to include more detailed instructions after it discovered certain vehicles were not properly serviced under the original recall campaign.gm revised the canadian recall campaign a second time to include more substantial changes to the throttle body, intake manifold, positive crankcase ventilation (pcv) and engine cooling systems to further reduce the likelihood of icing within the engine air intake tract.again, gm issued a technical service bulletin (tsb #08-06-04-009) to address the alleged defect condition in u.s. vehicles using the revised procedure.odi is aware of 28 non-duplicative complaints/field reports and 46 warranty claims related to the alleged defect affecting 63 unique subject vehicles.the alleged defect condition is most likely to occur during the winter months when ambient temperatures are below freezing.however, the information provided in gm's response to odi's information request letter dated november 2, 2007, does not capture events that may have occurred during the most recent winter months.accordingly, this investigation has been upgraded to an engineering analysis (ea08-005) to further study the frequency of the alleged defect. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 06/13/2011 | 65000 | ||
| Timing belt failure at highway speed. almost got into accident. chevy aveo only had 65,000 miles. | |||
| 02/28/2011 | 48000 | ||
| 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. | |||
| 02/20/2011 | 66000 | ||
| 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. | |||
| 02/28/2011 | 48000 | ||
| 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. | |||
| 02/20/2011 | 66000 | ||
| 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. | |||
| 02/28/2011 | 48000 | ||
| 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. | |||
| 02/20/2011 | 66000 | ||
| 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. | |||
| 01/24/2011 | 58000 | ||
| Chevy 2004 avero timing belt broke which also damage engine had to replace valves which cost over $1100.00. this incident happen when my wife was coming from therapy on a higway (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. | |||
| 12/28/2010 | 92941 | ||
| 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 problme. #1 no clearance between piston and valves. #2 faulty timing belt. | |||
| 12/05/2010 | 80000 | ||
| 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 engine...now 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. | |||
| 10/08/2010 | 55000 | ||
| 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. | |||
| 07/05/2010 | 59000 | ||
| Tl-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 was coasted to the side of the road and then towed to a nearby independent mechanic. the failure was contributed to the timing belt. the vehicle was not repaired. the failure mileage was 59,000. the vin was unavailable. js | |||
| 01/01/1901 | 59000 | 1 | |
| 2004 chevrolet aveo. consumer states the vehicle stopped in the middle of traffic on the highway *tgw the consumer stated the timing belt failed. *jb | |||
| 07/05/2010 | 59000 | ||
| Tl-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 was coasted to the side of the road and then towed to a nearby independent mechanic. the failure was contributed to the timing belt. the vehicle was not repaired. the failure mileage was 59,000. the vin was unavailable. js | |||
| 01/01/1901 | 59000 | 1 | |
| 2004 chevrolet aveo. consumer states the vehicle stopped in the middle of traffic on the highway *tgw the consumer stated the timing belt failed. *jb | |||
| 05/21/2010 | 41000 | ||
| 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. | |||
| 05/24/2010 | 92000 | ||
| 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 | |||
| 02/04/2010 | 59000 | 1 | |
| Timing belt failed, causing engine to fail while in traffic. engine was destroyed by the timing belt failure. *tr | |||
| 12/08/2009 | 46500 | 1 | 08/24/2009 |
| Tl* 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 *cn the timing belt failed and locked up the engine. updated 01/13/10.*jb | |||
| 06/19/2009 | 54000 | ||
| Tl* 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. | |||
| 03/25/2009 | 112000 | 1 | |
| The timing belt broke on my 2004 chevy aveo. i understand that this is a problem for alot of people. i contacted my local chevy dealership and they said i would have to replace the engine. *tr | |||
| 08/22/2009 | 60000 | 1 | |
| 2004 chevy aveo timing belt broke causing valves to break and many other related parts at 60000 miles. my mechanic said this is common in these cars and he doesn't understand why there has not been a recall. had i been aware of the problems with the timing belts going at 40-60000 miles it might only have cost me $50 to repair instead of $950.00. it is my understanding in my research since this occurred by speaking with mechanics ect. all are in agreement they don't understand why there is not something being done on these belts. we were stranded, cost of towing and lengthy and costly repair for what i am finding out to be a common problem with this car and the 2004 year. *tr | |||
| 03/21/2009 | 48000 | 1 | |
| My 2004 chevy aveo has had more problems than you can imagine. i had to replace the timing belt twice, severe engine damage both times. ocean chevrolet and gm were absolutely no help. rotors had to be replaced at 48,000 miles, an evap leak for another $600.00. both timing belt repairs were over $2000.00 each. i have put more into repairing this car than i paid for it. got runarounds from the dealer and gm and wouldn't recommend a chevy product to anyone. *tr | |||
| 04/08/2009 | 70000 | 1 | |
| First of all i learned on the internet that the chevy aveo is not a good deal when you are looking for a car. the first time the timing belt broke and spend a lot of money and now the thermostat housing broke because is made of plastic. like other aveo owners say, this car have to be recall, because all the problems it have. *tr | |||
| 12/17/2008 | 53470 | 1 | |
| 2004 chevrolet aveo broke timing belt at 53,470 miles. always serviced on time. no warning lights. also, have had electrical problems with car since buying. dashboard clock resets constantly. odometer reading fails. this is a dangerous car. *tr | |||
| 10/29/2008 | 20100 | 1 | |
| My car is a 2004, chevy aveo, with 23,100 miles. the temperature gage showed the engine to be overheating on my way to work on october 29, 2008. there were no warning lights, only a rambling engine sound and a burning type of smell. the reservoir tank was half empty and there was visible signs of leakage around the thermostat housing. the replacement of the thermostat housing remedied the failure. however, the thermostat housing from the factory is originally encased in plastic housing, but the chevy dealer retails the part with metal housing. the metal housing indicates chevy | |||
| 10/03/2008 | 61000 | 1 | |
| We have a 2004 aveo and no light came on and at 61,000 miles my car just quit running in the middle of the road and had to be towed to the dealership the timing belt had broken and the motor was messed up also. i had to pay over $3,000 to have it repaired cause a belt broke. it messed up half of the motor and had to be replaced. then a month later the lights on the dash quit working and they told me that they have replaced them alot for these cars and the wire harness is $1,200 dollars and i am paying more for the repairs then i have for the car. the clock light has never worked right since we got the car. so be careful and replace your timing belt early and don't have to pay all that money like we had to. i wish i have never bought the car now. *tr | |||
| 02/01/2008 | 2 | 10/01/2005 | |
| 2004 chevrolet aveo broken timing belt. consumer states that dealer stated that the problem was under warranty and replaced the valves because they were bent. consumer would like to know why the timing belt was not replaced. *kb the consumer stated a tsb had been issued for the timing belt problem. | |||
| 04/29/2008 | 102000 | 1 | |
| 2004 chevy aveo timing belt failure at 47,000 miles, and at 102,000 miles approx. 53,000 miles after the previous failure. both failures have caused severe engine damage. i have been advised that the most recent failure could result in an entire engine replacement. *tr | |||
| 01/10/2007 | 55000 | 4 | 06/06/2004 |
| Timing belt went on my chevy aveo 2004 in january. @ 55,000 miles and the belt damaged the whole engine. the gmc company refused to repair it. i found out that the chevy aveos are having lots of problems. *tr | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 10/17/2010 | 68000 | ||
| 2004 chevy aveo thermastat housing - cracked and overheated. tons of references on internet on this same problem. | |||
| 09/16/2010 | 112024 | ||
| Thermostat housing busted on the middle of highway causing car to immedeatly run hot | |||
| 05/26/2010 | 65000 | ||
| Thermostat housing busted for the 3rd time!!! | |||
| 05/21/2010 | 125395 | 1 | |
| Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6) my name is [xxx], i have a 2004 chevrolet aveo ls with a 1.6l engine. on may 21 of 2010 when i was on my way to school lodi ca, to sacramento ca, the thermostat housing cracked. i was unable to make it to class and had to pay over 100.00 dollars to get my vehicle towed. when i got the car home i noticed that the thermostat was made of a plastic material. how could something that flows coolant and holds such an important part of the cooling system be made of plastic. i then did some research on the part, and finding out that the thermostat housing has been replaced with a factory correct replacement. so this is not the first time it has happened to this vehicle. my vehicle is at 125,000 miles and has been well maintained, all necessary tune-ups, oil changes, trans. fluid changes, coolant flush, plugs, ect. i also know this is not the only aveo that this has happened to multiple times. this is an ongoing problem for the aveo. once again, why is something so important made of plastic? i feel that this is a safety hazard, for example, if the engine got to a higher temp. than it did, i would be looking at a warped head, are even worse, a cracked block. that could cause major damage and even a wreck. i also feel chevrolet should take responsibility in this poor judgment of a part. a recall should be issued and a better quality part should be used. i am now forced to replace this part without any assistance from chevrolet, and it is not cheap. i am a college student that bought this car for the economical and what i thought was reliability value. if there is anything you can do i would appreciate it. i and a lot of other people would feel a recall is due for the thermostat housing. [xxx] *tr | |||
| 04/14/2010 | 62560 | ||
| Smelled smoke got almost home saw smoke white in color opened hood and saw the housing on the thermastate was blown and fluid spraying out with steam | |||
| 02/03/2010 | 53000 | 1 | |
| 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. *tr | |||
| 08/14/2009 | 70000 | 1 | |
| Car: aveo 2004- 4d. the ac got damaged, then the blower. the car got overheaded and stopped working. $1,361 worth of work was done (machine work, head gasket set, gasket sealer, timing belt, sparks plugs, timing belt tensioner). two weeks after the car started overheading again and had a strong smell of gas. the mechanic recommended to buy a clip to adjust the gas hose!! and to put water to coool it down... the problem continued. i got tired and took the car to another mechanic who awknowledged the first mechanic assembled some things backward. less than an hour after picking up the car from the second mechanic and after i parked it...the car burst on fire... it is gone...gone! *tr | |||
| 06/29/2009 | 125278 | 1 | |
| I own a 2004 chevy aveo. the thermostat housing broke. you must replace the entire thermostat and the thermostat is not broke it works fine. there was no warning and the engine did not overheat. i do not think a part should break apart and if it does you should not have to replace a good part. the oil light flickered so i checked under the hood and the housing had steam coming out. *tr | |||
| 04/05/2009 | 70000 | 1 | |
| I was driving my 2004 chevy aveo (with 70k miles) and without any warning the engine starting making a lot of noise. i was about a block from home, and when i pulled in, smoke started pouring out of my engine. the thermostat housing had busted which is apparently a very common complain with this car, and the manufacturers are clearly aware of the issue since they have made the replacement part out of metal. i don't know yet what kind of damage the engine has sustained. *tr | |||
| 03/20/2009 | 54000 | 1 | |
| I was driving down the road and smelt burning fluid and thought it was another car on the road. after the car wasn't close to me anymore i smelt the same odor. i looked down at my thermostat to see my car was in the red, no check engine light had come on or anything. i pulled over and noticed immediately that my thermostat housing(which is plastic and a poor design) had cracked in half right along the seam.i have read that this problem has lead to very expensive repairs due to the fact that it warps the heads right away and it can be easily prevented by a better quality part and / or design.this could have been a very dangerous problem if i had been going down a hill, far from a parking spot, on the freeway etc. do something about it. *tr | |||
| 09/05/2008 | 1 | ||
| We purchased a preowned chevrolet aveo within aprox a year (low mileage still under warranty, also purchased extended warranty & gap insurance), taken very good care of it, including routine services as needed. suddenly 3 weeks ago without any warning at all the engine blew.. no steam, no gage warning, no warning lights, nothing. suddenly the engine light came on & within less than 30 seconds engine blew while driving with no warning. we had it towed to a mechanic who determined that the thermostat had went bad causing the engine to blow. we decided to have it towed to the dealership in order to process our warranty and possibly trade it in.. the service dept at the dealership states that without taking apart the motor all they can truly say is the car got hot and the engine blew. once again, i stress- no steam, no raised temp in gauges or check lights came on. we had no warning or notice of any problems with the car. after 3 weeks the car is still sitting unusable at the dealership service dept until we decide what we are going to do, as we wait on having more diagnostic work done to file with the warranty. we decided to do some research on the car and found hundreds of complaints identical word for word on what happened to us- all stemming from thermostat and engines randomly blowing up without warranty. we have printed all of these out to present to chevrolet & our dealership where our car currently sits unusable. we have already contacted chevrolet, & our warranty company in hopes to find a resolution and we wish/hope a recall will be issued for the many cases like ours. i am willing to provide any proof if needed. this car has many complaints and commonly this complaint regarding sudden engine blowing up.. the part that has us upset is that the manufacturer and dealerships seemingly aren't taking responsibility for this and many people are losing money and possibly safety in their cars because of this issue. please help us. *tr | |||
| 08/17/2008 | 53963 | 1 | |
| My 2004 chevy aveo broke down in the middle of an intersection at 47,652 miles. the car wouldn't start and couldn't be moved while my daughter and grandson were stranded in traffic. the problem turned out to be the timing belt which should have lasted 2x the mileage. then engine rattled after that repair. on 17aug08 my car started smoking from under the hood. when i opened the hood, antifreeze covered everything. i took it to the dealer who told me the belt tensioner was bad causing the rattle and the thermostat housing cracked causing the antifreeze to spew upward and cascade over the top of the entire engine. *tr | |||
| 12/24/2004 | 723 | 1 | 12/01/2004 |
| Purchased a 2004 chevy aveo from mccluskey chevrolet in reading ohio-on december 12/01/04. vin # klitd526x4b196935. on december 24, 2004 our car of almost 4 weeks old broke down on us at approx: 2:45 pm. we notice smoke coming from the engine and a gurgling noise. my husband lifted up the hood and there was a milky substance on the upper left hand in front of driver's side under the hood. we called and had the car towed on x-mas eve day. it had taken the towing service over five hours to tow our vehicle. we had to be inconvenienced and find a ride home. then we did not have a vehicle until december 27, 2004 at around 5:55pm. my husband called the dealership and talked to the sales person who sold us the car he basically told us that they are not responsible for the vehicle now and it is the hands of the manufacturer. my husband has made several phone calls to the service dealer who has the vehicle for the repair they stated several times to him on the phone that they did know what the problem was with the car. still no answer. nothing to date has been done to the vehicle to date. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 04/21/2010 | 81000 | ||
| On my daughters 2004 chevy aveo i had the timing belt, water pump, and t'belt tensioner replaced at 59826 miles, per manufauctures reccomendation. about 20000 miles later the idler pulley broke, destroyed engine. gm has not recommended replacing this part per their maintenance schedule , why not? | |||
| 04/05/2010 | 45000 | ||
| 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! | |||
| 03/30/2010 | 95000 | ||
| Engine destroyed by timing chain failure.timing chain failure resulted in damaged pistons and valves.vehicle had 95,000 miles on it. | |||
| 03/26/2010 | 55000 | ||
| 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 dealships been informed. a closer inspection of my car revealed that the idler pulley, which is made of plastic, melted and melded itself to the engine block, which is what caused the belt to break. | |||
| 03/18/2010 | 97000 | ||
| 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 | |||
| 02/03/2010 | 53000 | 1 | |
| 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. *tr | |||
| 02/04/2010 | 59000 | 1 | |
| Timing belt failed, causing engine to fail while in traffic. engine was destroyed by the timing belt failure. *tr | |||
| 01/14/2010 | 1 | ||
| 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. *tr | |||
| 05/20/2009 | 99999 | ||
| Tl*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. | |||
| 08/15/2009 | 13400 | ||
| Tl*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. | |||
| 09/12/2007 | 49000 | 1 | 04/23/2004 |
| Tl*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. | |||
| 04/21/2007 | 70000 | 1 | 04/20/2004 |
| 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. *jb | |||
| 10/21/2004 | 5200 | 3 | 05/13/2004 |
| Fuel injector stuck open making a loud tick. gm told me it was a lifter engine is dohc. *jb | |||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||
| 06/28/2007 | 60331 | 1 | 07/01/2005 |
| On thursday morning 28 june 2007 the timing belt on this chevrolet aveo broke, resulting in catastrophic damage to the engine. the vehicle was towed to radley chevrolet, where this diagnosis was rendered. radley chevrolet held a new car owner's orientation class at which their services and hours were discussed. class topics included timely oil and filter changes. no mention was made,or emphasis placed, on the need for inspection of the timing belt at 30,000 miles or its replacement at 60,000 miles. when i mentioned this recently to the radley chevrolet general manager he responded by telling me that all chevrolets made in the usa use timing chains instead of timing belts. hence his staff would not think to emphasize the need to inspect and change the timing belt. it appeared that this lack of concern or training may have extended to some maintenance personnel. i was not advised of the need for this inspection at either of the two oil changes, performed by radley around the 30,000 mile point. the timing belt failed at an odometer reading of 60,331 miles. the 331 miles beyond the 60,000-mile recommended replacement point suggest that the odometer has an accuracy better than .55%. considering the technology used to measure speed and mileage in vehicles sold to the public it is not likely that any are so accurate. had observed that in driving from alexandria, virginia to fredericksburg, virginia she was often among the slowest on the road in spite of speedometer readings that suggest she was driving well above the posted limit. on several occasions she had her husband record the elapsed time between mile-posts and found that they were traveling around 5 to 6 miles per hour less than the speedometer reading. this amounts to an odometer reading from 6.25% to 8.5% greater than actual distance traveled. hence at an odometer reading of 60,331 miles, actual mileage is between 56,560 and 55,203 miles. *ak | |||
| 07/09/2004 | 32 | 4 | 06/22/2004 |
| Tl*-the contact owns a 2004 chevrolet aveo and stated that since she purchased the vehicle the passenger's side seat belts never locked correctly in place. she took the vehicle to the dealer, and they replaced the seat belt, but she believed that they switched it from the front to the back. currently, the seat belt has been locking when anyone sat in the back. also, the dome lights iwere constantly burning out. this had occurred about three or four times. in addition, the clock did not work whenever she set the time, it would change on its own accord. similarly, the key lock on the driver's side fell through the door panel. the dealer repaired and painted the door the wrong color, and they painted over the door handle. just last week finally, the tension pulley fell off while she was driving on the freeway. they told her this was normal wear and tear on the vehicle and refused to make further repairs. the failure mileage was 32, and the current mileage was 60,750.*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 12/10/2007 | 54541 | 1 | |
| Timing belt broke prematurely at 54541 miles. gm owners manual says to change it at 60000 miles. car was worked on by gm under there special bulletin for this problem. however the car had to be returned to the dealer, this time it 56870 miles on it when the ses light came on i took the car to aamaco on saturday because the dealership was closed some of the codes were my transmission i was told it wasn't going in 4th gear and burned my transmission fluid. so i had my transmission serviced at my expense by the dealership. the dealership told me that gm had the part #'s listed wrong and they had installed the wrong parts when they had worked on the car the first time. so now they put in new parts and the car still doesn't run right. they tell me i need new plugs and wires and that the cost would be 300.00. i told them no way i was given them 300.00 for 4 plugs and 4 wires. so they ended up changing the plugs for 32.00 and i changed the wires myself. at 56987 miles car goes back to dealer third time, ses light on, cause : intake manifold tuning solenoid disconnected and timing belt to tight. at 57012 miles a c/s ses light on, cause; low efficiency the dealer replaced the catalytic converter due to the timing belt. car has never run right after these attempts of repairs and now sept. 2008 ses light comes on again the has 66200 miles on it. took it to the dealer and they told me i needed new wires and plugs again and that they could not do anything if i did not let them change them. this is just another case of gm not standing behind there products that fail. *tr | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 06/20/2007 | 34000 | 1 | 02/02/2007 |
| 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. *tr | |||
| 08/10/2007 | 1 | 03/08/2005 | |
| 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. *jb | |||
| 01/10/2005 | 5000 | 4 | 07/23/2004 |
| 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. *ak | |||