2004 Chevrolet Aveo Service and Repair Manual

This factory service and repair manual for the 2004 Chevrolet Aveo covers a small car sold in two shapes on one powertrain. The engine is the naturally aspirated 1.6L DOHC inline-four of 98 cubic inches; the bodies are a four-door sedan and a four-door hatchback; the trims number two, Base and LS. Engine, fuel, ignition and emissions procedures are written once for the four-cylinder, while the body, glass and trim sections separate where the sedan and the hatchback part company, and the specifications and torque values follow each system.

Engines covered

• 1.6L inline-four (98 cu in) — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 4-door hatchback

Trims covered

• Base
• LS

Known issues on the 2004 Aveo. Two recalls stand on the federal record. In one, the daytime running light module in the center console can generate enough heat to melt itself, with a vehicle fire as the outcome. In the other, a rear safety belt can twist, which locks the retractor and leaves the belt unusable in a crash. Owners have logged 206 complaints, the largest share on the engine and engine cooling at 61, followed by the electrical system at 31 and air bags at 21 — the cooling, body wiring and restraint diagnostics this manual sets out.