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Chevrolet Aveo Maintenance and Repair

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  • keep looking back on this site threr are at least 8 other people since 2007 who has had the same problems. i was unsuccessful with the dealer and customer service complaint line. something must be done
  • My Chevy Aveo thermostat housing also broke apart. Composite plastic which is the material is made off might be strong enough, but since the housing is made in two parts, so part maker can install the thermostat and gasket, this parts break apart, because they are put together not even with glue, but by heat.
    When the engine moves, or the radiator moves because it is attached to the body, the housing will break. If an engine mount is in bad shape,the problem will occur more often.
    The solution is to get a metallic housing that has been available for a long time. In fact GM decided to use the plastic one, because it is cheaper, but leaves the driver exposed to a failure that can go undetected since the temperature sender will not send a proper reading, showing a lower temperature, since the sender requires coolant to properly read, so the only hint to this problem could be steam coming off the engine or a spill, but sometimes this is hard to see. If this happens, blowing the gasket or seizing the engine is a possible scenario.
    Anyway. I got tired of this problem after a second housing broke on me. Now, with the metal housing I think I solved the problem. It was more expensive, in fact dealerships wanted 90 dollars for it, but I found it on Ebay for 70, so it wasn't that bad.
    Another thing that I wanted to talk about is the timing belt and the water pump. The engine on the Aveo was designed for high compression, but because of space and engine size designer was force to reduce the size of the compression chamber and to install 4 valves per piston, which is fine, excepting for the use of a timing belt instead of a timing chain, which is acceptable, excepting that sometimes the belt breaks and then the pistons, that are very close to the valves, end up hitting them and getting bend, and this actually means a very expensive repair.
    The type of engine is widely known as an interference engine, and it is commonly used in the car industry, but some car makers install good quality components that will last 100 K or even more.
    Some people will say that is way you have a preventive maintenance schedule, which is true, but there are a lot of things that could drive the timing belt to fail prematurely, such as oil, dirt, water and poor quality rubber on the belt itself. On top of that, preventive replacement of timing belt is not precisely cheap, since belt is more or less hard to replace.
    To make things worst, the engine design makes the timing belt to drive the coolant or water pump, so if the water pump seizes, then the belt will get destroyed, hence the engine will as well.
    To top that, tensioner and idler pulley are made also in plastic and bearings are short lasting, so they could also seize, and then engine will also get destroyed.
  • You could do it, but you have to lawyer up. If you probe you were not able to read the temperature, since the temperature sender works properly only when there is coolant, water or other fluid, then you were not able to asses the engine was overheating, so you could not be deemed negligent since you were not able to determine the magitude of the problem.

    My Chevy Aveo thermostat housing also broke apart. Composite plastic which is the material is made off might be strong enough, but since the housing is made in two parts, so part maker can install the thermostat and gasket, this parts break apart, because they are put together not even with glue, but by heat.
    When the engine moves, or the radiator moves because it is attached to the body, the housing will break. If an engine mount is in bad shape,the problem will occur more often.
    The solution is to get a metallic housing that has been available for a long time. In fact GM decided to use the plastic one, because it is cheaper, but leaves the driver exposed to a failure that can go undetected since the temperature sender will not send a proper reading, showing a lower temperature, since the sender requires coolant to properly read, so the only hint to this problem could be steam coming off the engine or a spill, but sometimes this is hard to see. If this happens, blowing the gasket or seizing the engine is a possible scenario.
    Anyway. I got tired of this problem after a second housing broke on me. Now, with the metal housing I think I solved the problem. It was more expensive, in fact dealerships wanted 90 dollars for it, but I found it on Ebay for 70, so it wasn't that bad.
    Another thing that I wanted to talk about is the timing belt and the water pump. The engine on the Aveo was designed for high compression, but because of space and engine size designer was force to reduce the size of the compression chamber and to install 4 valves per piston, which is fine, excepting for the use of a timing belt instead of a timing chain, which is acceptable, excepting that sometimes the belt breaks and then the pistons, that are very close to the valves, end up hitting them and getting bend, and this actually means a very expensive repair.
    The type of engine is widely known as an interference engine, and it is commonly used in the car industry, but some car makers install good quality components that will last 100 K or even more.
    Some people will say that is way you have a preventive maintenance schedule, which is true, but there are a lot of things that could drive the timing belt to fail prematurely, such as oil, dirt, water and poor quality rubber on the belt itself. On top of that, preventive replacement of timing belt is not precisely cheap, since belt is more or less hard to replace.
    To make things worst, the engine design makes the timing belt to drive the coolant or water pump, so if the water pump seizes, then the belt will get destroyed, hence the engine will as well.
    To top that, tensioner and idler pulley are made also in plastic and bearings are short lasting, so they could also seize, and then engine will also get destroyed.
  • About two weeks ago my girlfriend called me and said she pulled over because her 05' Chevy Aveo was smoking.. I told her to look at her thermostat and she said it as normal.. When I came to her rescue. We found that the thermostat housing snapped on the seam and the coolant was spitting out.. We towed it home..I called around for the housing and it is a dealer part only! Found out this part has been updated and it is no longer a plastic part and it retails for $95.00!
    We replaced the part.. A quick and easy fix! then a week later.
    my girlfriend was on her way home from work.. Her car just stopped accelerating.. it felt like it wasn't getting enough fuel.. So again pulled over on the side of the freeway we tow it to the shop... my mechanic does a full diagnostics and finds water on the spark plugs.. He called and asked me does you car drive hot.. I told him never..I told him that about a week earlier the thermostat housing snapped and the coolant came out we replaced the part and no problems since.. Well he put it all together.. When the housing broke, almost immidietly it caused my heads to get hot and wrap and then water to get into my oil. Now with wrapped heads he started the car but its only a matter of time before it blows.. So do i wait.. No because it will cause more serious damage to the engine.. we need to get the head fixed .. now i am looking at closer to a 1000.00 bucks for something that could have been prevented .. by a simple letter from Chevy stating that thermostat housing is faulty, made of plastic and has been updated to a aluminum part.. well what do we do now! i see allot of posts about the same issue! lets act now! :lemon:
  • this just happened to me today and when i did an internet search to find a new thermostat this was the first thing that popped up. this really irritates the heck out of me. this is about the 4th repair ive made on the car and its only a 2004. im having a new thermostat overnighted to me. Ive never seen a thermostat like this, what were they thinking when this piece was designed. I wish i new this was a daewoo when i bought it, i was under the impression that it was a chevy design this forum was the first i heard of it being a daewoo untill i called the dealership today and the service guy told me the same thing. this really makes my blood boil. first i had a seat belt issue then a water pump and brakes that wore out in record time only to find out that the rotors cost a fortune.
  • marlanmarlan Posts: 1
    Yesterday morning I noticed a strange smell while I was driving to work but thought it could be another car on the freeway... But when I drove home last night, just as I was parking, white smoke (steam?) started pouring out from under the hood. I immediately turned off my car, freaking out, and didn't think to check the gauges... But I noticed some liquid under the hood, passenger side, spilling onto the headlight as someone else mentioned here. Couldn't see where it was coming from and honestly I was so distraught I didn't really look for the problem; I just wanted to get in my house and forget about it for the night. Now that I have done some research and talked to mechanically-inclined friends, I'm almost positive it must be the thermostat housing. I will look under the hood again later today to find out.

    I rarely use my AC but did notice it wasn't working a month or 2 ago... The fan was obviously running but there was no cool air coming out, just a weird smell-- similar to the awful odor that came out when it started smoking yesterday. Does this make sense? Could it be a different problem?

    It's a 2004 Aveo with just over 59000 miles on it. I'm still under the GM Major Guard Protection Plan (but not for long!) but I don't know if this would be covered under that... Anyone know about that?

    Anyway, I just wanted to add to this discussion and let everyone know that this is an issue with MANY Aveo owners and it seems to be occurring more and more as of late (probably because the folks who bought the 04 and 05 models are starting to reach 50-60k miles). If everyone who has this same situation speaks up, hopefully GM will issue a recall...
  • I had the exact same thing happen to me, driving up hill, no warning whatsoever. Just a burning smell & smoke from under the hood. As soon as I opened it you couldn't miss the cracked housing, it was perfectly in half at the seam. My dad installed it for me, car was great for about 3 days, then it didn't want to start. It was taking forever, as long as 15 minutes, took it to the dealer, they refer to it as a "slow start". My car had a little under 45k miles, they claimed it needed spark plugs & wires. The maintenance schedule says wires s/b replaced @ 65K miles. It took them 2 days to figure it out, charged me $400. 3 days after I got it back from the dealer, same exact start problem!!! It's as if it's not getting fuel, it struggles to start, then the HOLD light stays on as the car is shaking, like it wants to die. I immediately turn it off & back on and then it's fine. Of course it's not doing it on every start so they can't attempt to solve the problem unless it actually occuring. Then today out of the blue, after another "slow start", the A/C starts blowing hot air after being on for less than 10 min. I turned it off for a couple of minutes and then turned it back on and it was blowing cool air again. It happened twice today. Does anyone have any suggestions before I take the car back to the dealer? :lemon:
  • its a warped head! if you keep driving it you will cause more damage to your engine like a cracked head... i just got mine back from the shop ... 1000 in parts and labor...
    when ur thermostat housing broke it cause your heads to warp immediately! i know it sounds crazy but these aluminum heads cant handle it. it took my mechanic a couple day to figure it out also. but once i told him my thermostat housing broke a few days b4 it all came together! there is water getting on your spark plugs and water mixxing with oil. :lemon: :lemon: :lemon: :lemon: :lemon:
  • Well, it's not good news, but at least you've given me some direction. Before they did the plugs and wires all they could tell me was the battery was fine, they didn't know what was wrong. I had to repeatedly tell them it was like it wasn't getting fuel.

    The gear shift was also stuck, they had to replace a stop lamp switch & filter for it.

    The only warranty left is the Power Train Warranty, does anyone have any idea how I find out what that covers? :sick:

    I encourage everyone who has had this problem to file a complaint so we can try & get a recall. report a vehicle safety issue to NHTSA online at vehicle safety Web site: www.safercar.gov
  • This is an update to a posting I did back in August when my thermostat housing broke, last night I drove to the store and when I go back into my car the car started to shake and vibrate then the HOLD LIGHT was flashing. I turned it off and then on and then its fine, lucky the store was only 4 blocks away. What the hell is going on with this car, I hope CHEVY RECALLS these pieces of junk they call cars, I have had nothing but problems since I got it, and now its starting to smell like burn oil. Anyone has had the same problem?
  • tomh4tomh4 Posts: 7
    When I got this car BRAND NEW it had a bad CV, it was clicking as I left the lot :(
    So they fixed that then my thermostat housing busted just like the rest of you guys :(
    I fixed that because I didnt want to tow it to the stealer and leave it their for a $20 part that took me 5 minutes to replace :(
    Then the key lock in the drivers door fell into the door, so now I cant lock the drivers door :( The stealers told me it wasnt covered because it was a trim piece (Same thing happened to my buddies Aveo)
    Then my brake lights stopped working, again the stealers wouldnt cover it so again I had to fix my brand new car thats still under warranty myself :(
    This car is a disposable POS I wish I never bought it.
    It will be paid off this Feb :(
  • I hate to tell you this, but that sounds exactly like what my car was doing. My daughter called it the roller coaster because it shook so much.

    Unfortunately, my car is @ the dealer, suspected cracked Head Gasket. Today they called and said they took out the Cylinder Head and sent it to see if it could be repaired or had to be replaced. They also believe it will be covered by the Power Train Warranty because there's no signs of neglect/misuse.

    Everyone need to file a complaint with the NHTSA so they can investigate & get a recall, if no one complains to them nothing will be done.

    www.safercar.gov
  • poncho167poncho167 Posts: 1,178
    Because its not a safety issue the NHTSA won't do anything about it.
  • aveo36aveo36 Posts: 1
    Just today my green tick tack (aveo) thermostat broke and i didnt notice untill I looked my gages and it was on the red. But again like many others there was no indicatore lights letting me know something had happen. I cant believe that the thermostat housing is made of plastic. Thats CRAZY anyways I plan to replace the housing but hope nothing bad has come of this incident.<img src="
  • I fixed it and the dealer gave me another plastic housing. Chevy should recall these cars, well after that the HOLD light started to flash and the car shook. I called Chevy and they said "well you have to take it in" sorry. Like if they did not care. oh well good luck to you
  • what is with this car first i have a seat belt belt break then the drivers door lock falls into the door so i can't lock the door any more now my thermostat houseing cracks in half i bought the car new in 05 and have 42,000 miles on it whats next :mad: :sick: :mad: :sick: :mad:
  • It looks like my problem is common in source, but perhaps not as much in severity. I was driving about 10 minutes from my home when check engine light came on. I did not notice any significant issues with performance. Drove home, turned off car. Tried to start it 3 days later and it would not start. Engine will crank, but car will not start. Borrowed an ODB II diagnostic from AutoZone and got the following codes:

    P0128
    P0128 PENDING

    These codes on an '04 Aveo, apparently, usually mean the thermostat housing is busted. But, I never saw any smoke or noticed any performance problems. Is it possible that the thermostat busted and resulted in damage to engine, like a warped gasket or something, that would cause it not to start? The car is at 42K miles, past bumbper to bumper warranty but still in powertrain warranty which covers engine parts and towing for powertrain problems. Any advice? :sick:
  • poncho167poncho167 Posts: 1,178
    I can't say why your car won't start but that wouldn't happen from warped heads.

    I assume that you have lights and all. Have you played around with the shifter to see if it is not hung up in a position other than park.
  • Mine having a "delayed start" as the dealer called it, was a direct result of the warped heads.

    It made the sounds like it wanted to start but wouldn't turn over for several minutes sometimes up to 15 minutes.

    I had it towed to the dealer, signed the estimate for the diagnostic, they found water in the the oil (1 week after they changed the oil). They couldn't tell me if it was a cracked or warped head or if it would be covered by the warranty until it was taken apart but they were 80% sure it would be, so I had to agree to an $800 revised estimate just for labor.

    It took almost two weeks but it was covered and it was not machine repairable, they had to put in a whole bunch of new parts.
    I suggest you take it in for them to diagnose it, you can't get better than warranty coverage.
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