2004 Chevrolet Aveo Service and Repair Manual

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Factory-Grade Data

2004 Chevrolet Aveo service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • LS Hatchback 4-Door
  • Base Hatchback 4-Door
  • LS Sedan 4-Door

Engines covered

  • 1.6L 1598CC 98Cu. In. l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Chevrolet Aveo Recalls & Complaints

NHTSA #04V40700017/08/2004Component: SEAT BELTS:REAR/OTHER

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 U

Remedy

DEALERS WILL INSTALL A SAFETY BELT WEBBING GUIDE TO PREVENT THE BELT FROM TWISTING. THE R

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

TSB #11004761

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should

TSB #11004557

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

TSB #11002312

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

TSB #11000576

This Warranty Administration bulletin provides retail and wholesale service personnel with the policies/procedures and the warranty transaction submission procedures that support the Personal Property Damage process.

Showing the 8 most recent of 183 technical service bulletins on file with NHTSA.

20150212Component: ELECTRICAL SYSTEMCrash reportedFire reported

TL* THE CONTACT OWNED A 2004 CHEVROLET AVEO. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V2610000 (EXTERIOR LIGHTING). WHILE DRIVING APPROXIMATELY 40 MPH, THE CON

20150212Component: EXTERIOR LIGHTINGCrash reportedFire reported

TL* THE CONTACT OWNED A 2004 CHEVROLET AVEO. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V2610000 (EXTERIOR LIGHTING). WHILE DRIVING APPROXIMATELY 40 MPH, THE CON

20050223Component: AIR BAGS:FRONTALCrash reported3 injured

I WAS IN A CAR WRECK WHERE A WOMAN SHOT ACROSS IN FRONT OF ME AND I HIT HER IN THE PASSENGER SIDE OF HER VEHICLE AND IT WAS A SOLID IMPACT FOR MY VEHICLE AT ABOUT 25-35 MPH. AND MY

20041014Component: SEAT BELTSCrash reported2 injured

THE CONSUMER WAS INVOLVED IN A VEHICLE ACCIDENT WHEREBY THE SEAT BELTS DID NOT WORK. THE DRIVER SEAT BELT BROKE AND A TODDLER WAS THROWN TO THE FRONT SEAT. AFTER COMPLAINING TO T

Showing the 4 most serious of 271 complaints filed with NHTSA.

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