Engine Cooling System Problems of Chevrolet Aveo - part 1

2010 Chevrolet Aveo. Consumer writes in regards to a faulty radiator and unsatisfactory customer service at dealership. The consumer stated in September 2013, he started experiencing problems with the cooling system, where the temperature gauge would start to climb above the halfway point. Thinking it was just loss of coolant, he added more to the reservoir, but to no avail. He decided to take the vehicle to the dealer and it was determined a radiator part was faulty. The radiator and thermostat were replaced at a cost of $1,000. It took a week and a half, before the vehicle was returned to the consumer. Tow months later, while driving, the check engine light illuminated, when he arrived to his destination, he exited the vehicle, but didn't find anything ut of the ordinary, he resealed the gas cap, because he knew sometimes, that could cause the engine light to illuminated. However, later on when he tried to drive home, the vehicle would not shift gears or go over 40 mph. The consumer took the vehicle to a friend, who was a mechanic. An inspection revealed it was a transmission problem related to the installation of the radiator two months earlier. The vehicle was taken back to the dealer, where the repair was made, under the power train warranty. Four days after getting the back, the consumer noticed a hose was hanging from underneath the vehicle. The consumer called his mechanic friend again, where he discovered the technician at the dealer, did not re-attach the transmission to the radiator. The vehicle was towed back to the dealer.

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The contact owns a 2005 Chevrolet Aveo. The contact stated in the engine coolant that the plastic elbow shattered causing the vehicle to over heat while driving 60 mph. The thermostat started running hot and the vehicle was smoking. The contact drove onto the emergency lane and as the hood opened the plastic piece on the thermostat blew apart. No one was injured. The vehicle was towed to a mechanic. The plastic component on the thermostat had to be replaced with a metal piece. The dealer was notified of the failure and offered no assistance. The manufacturer was not contacted. The failure mileage was 73,000.

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I do have complaint that I would like to file. It is regards to 2004-2007 Chevrolet Aveos. I had bought my 2005 Aveo brand new from chevy. It is now my sons car. He was driving the car at 45 mph came to a stop light and the car just stopped. What had happened is the thermostat housing had blown apart. It is a 2 piece plastic piece of junk. A thermostat housing should never blow apart. In 2008 chevy starting putting metal ones on the car. One week before this happened my son was traveling with his 2. 5 year old daughter in the back roads of PA heading down to visit his grandfather. If this had happened at that time there are long stretches of desolate road and with the mountains many times cell phones do not work. He and my granddaughter could have been in a lot of trouble. I cannot believe that this has not been brought to your attention before, it is all over the web. I will include some links below. This problem warped the head and could have done lower engine damage and chevy just walks away, not our problem. Anyone who knows about cars knows a thermostat housing should not blow apart. Chevy has put an inferior quality that is prone to failure in a critical area of a cars cooling system. There was nothing mechanically wrong with this car prior to this incident. . Read more...

2005 chevy Aveo broken timing belt warped valves after 89,535 miles. Car was never inspected by dealership prior to selling car. Taken in numerous times because of check engine light on or flashing. Purchased car 5-21-10.

While driving I noticed a smoke coming from under the hood. I looked down to see my engine temp indicator on hot. I wasn't far from my home luckily at the time, so I drove it home. I opened my hood a couple minutes later to find water sizzling on my thermostat housing. (which is constructed of two pieces of plastic, glued together) I tried to look up info on it and came across all kinds of people complaining about this exact same problem with their 2004-2005 chevy Aveo LS. The earliest complaint I saw was as early as January of 2009. After looking at your website, I found out that there is no recalls on this item at all. Also, the only place to get a new one is at the dealership for $91. 00 and that is without labor cost. In addition, it is not covered under warranty.

The thermostat housing broke from the engine block and burst through the plastic housing. I was on the freeway coming home from work when steam began pouring out the exhaust and from under my hood. Last year, a plastic bolt on the engine broke and sent two rods through the manifold; I got a new engine. I would think twice about this car.

2004 chevy Aveo thermostat housing - cracked and overheated. Tons of references on internet on this same problem.

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Thermostat housing busted on the middle of highway causing car to immediately run hot.

2005 chevy Aveo: plastic thermostat housing broke, spraying motor with coolant, shorting out plug wires and warping the head. The car has 78,000 miles. Requires head replacement/ repair, and gaskets.

Driving home from work on 8/26/2010, the thermostat housing just split in have on my 2005 chevy Aveo LS. The antifreeze spilled out and I needed to have the car towed. The thermostat housing is made of cheap pvc pipe like material and is in two pieces that appear to be glued together. A very low grade risky design in my opinion. The replacement part is only available from a gm dealer at a cost of $98 plus tax. The replacement part is made of sturdy aluminum. It appears to be a better design and structurally sound. My complaint is, gm obviously knew this part was substandard. Evidence of that is the reengineered replacement part. Gm should have recalled the chevy Aveo's and replaced the cheap/defective thermostat housing instead of not informing owners of the defect, and allowing the part to fail on the open road. Further, the cost of $98 plus tax for the upgraded thermostat housing should not passed on to the owner/customer. Gm should refund that cost and/or recall the vehicles for free replacement. This is a safety concern, especially when you break down on a interstate highway, in a small compact chevy Aveo, with small children in the car. I have read hundreds of blogs online of chevy Aveo owners this same part has failed on (after mine failed). It's appalling that there has not been a recall on this issue, and that the NHTSA has not forced gm to recall the vehicles with this cheap/faulty thermostat housing. It's not only a safety issue, but no engine light comes on when this happens, so a person can continue driving and cause further serious damage to the car if the engine block seizes up, etc.

My 2004 Chevrolet Aveo's thermostat housing busted today at 67,000 miles. This resulted in over heating the motor and dumping about one gallon of anti-freeze on the roadway. It turns outs this part was made out of plastic. A replacement aluminum version is now available by the dealer for $95.

2306 Chevrolet Aveo lt thermostat housing consists of two plastic parts glued together with thermostat between the two halves. The glued joint came apart and the thermostat fell out on the road. The coolant pumped out and the engine severely overheated. Towing charges from a remote highway location were $190. Repair at lamb Chevrolet in prescott, az, totaled $195. This was found to be a common Aveo problem and should have been a factory recall item!.

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Thermostat housing busted for the 3rd time!!!.

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].

I have a 2009 chevy Aveo which I wish to god I had never bought I have had nothing but trouble with the cooling system and emission system in this car I have replaced every sensor on this car I have had my air conditioner fixed three times and it keeps going out. My hold button is continuously on when in turn the a/c doesnot work this car should be recalled and not allowed to be on the road , I will never buy another chevy as long as I live I cannot believe the complaints on these cars and not a recall.

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The contact owns a 2005 Chevrolet Aveo. While driving 50 mph, the thermostat failed and the vehicle began vibrating and lunging forward. The contact took the vehicle to a local repair shop. He was advised that the antifreeze/coolant was spilling onto the engine, causing the vehicle to vibrate. The contact is concerned that the failure occurred since the thermostat and housing were made out of plastic and mounted into the vehicle with adhesive. The manufacturer stated that there was a metal replacement part being manufactured. The VIN was not available. The failure and current mileages were approximately 70,000.

Smelled smoke got almost home saw smoke white in color opened hood and saw the housing on the thermostat was blown and fluid spraying out with steam.

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.

The clock on my 2005 chevy Aveo does not work continuously. Sometimes the display works and sometimes it does not. As for safety issues, the plastic thermostat housing broke while driving down the road last week. After pricing replacement plastic parts, we opted to purchase the metal one, which can only be purchased from the dealer and which is more than twice the price of the plastic ones. We still had a leak, so we called a local napa store and purchased a gasket for under $2. After removing and then attempting to replace the part again, one of the bolt holes broke off. Isn't the metal supposed to be more durable? all this has happened in less than a week and the dealer refuses to stand behind the part. Not only was the plastic piece shoddy, so is the metal one and so is Chevrolet's customer service.

Blower motor not working low to med speeds. Blower resistor connector and blower motor defective. This is a manufacturer defect. I have been to the dealership 4 times for this same problem. I am very concerned for me and my families safety. I am concerned about a possible fire because of the blower motor not working correctly. The problem first occurred at 4,900 miles. It continues to fail at my current mileage 16,000.

The thermostat housing blew apart and I was 75 miles away from home on a Sunday. I replaced it with and 12 days later it blew apart again. My car has been in a reliable garage now for 2 weeks and they can't get the part. No local dealers have the part and the warehouse is "out of stock". I had a 7 year old child in my car. This should have been a recall by gm and I intend to go as far as the ceo if I have to. This is costing me a great deal of money to rent a car. I want my money back from gm along with a letter of apology. Shame on them.

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!.

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.

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.

Normal driving of vehicle plastic thermostat housing unit broke in half and exploded coolant over the engine and windshield of vehicle. Called the dealer and was informed that they know that the part is faulty and wears out in under 40,000 miles and have redesigned the part using pot metal which will now cost 89. 99 to replace. This is the second time we have had to replace this same part on this car in the three years we have owned it. So they know the part is faulty and then charge five time what the original parts replacement cost was because they know you have to replace it through them.

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.

My daughter was driving our 2005 chevy Aveo when she noticed smoke coming from under the hood, she contacted me and I came and saw anti-freeze all over engine compartment, it is when I noticed the thermostat housing split at seam. We got the car home using 3. 5 gallons of anti-freeze and several stops to let engine cool. I have read hundreds of postings on different websites with people having the same problem. This part is two plastic parts sealed together with the thermostat between them. I have noticed that chevy knew of this problem happening from 30k-50k mileage on the vehicles and the new replacement part is now metal. Once I get the part and install it I will have to pay to have the engine checked since most of the complaints also mention the head warping due to the heat caused by the thermostat housing breaking.

Thermostat housing broke in half causing overheating and internal engine damage.

Thermostat housing broke at the seal.

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.

Was driving on the expressway, when the thermostat housing broke. The car's mileage was 34, 500. Called dealership since the was still under warranty and the dealer told me that the part was not covered. I had to pay upfront for the part and had it replaced. Also the car now starts to shake and the hold light keeps flashing. This happens about twice a week.

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.

In the beginning I had no problems with the car whatsoever. Then the thermostat housing blew apart causing the engine to overheat and blowing the head gasket. Neither chevy or my extended warranty company (Toyota) would cover the repair. I had to spend over one hundred dollars on just the thermostat housing and over three hundred to get the problem diagnosed. The car still sits in my driveway broken. I had to spend another four hundred and fifty dollars to get the head repaired and to buy the new gaskets. Just got the car back together and still doesn't run right.

Back in may of 2008 I picked my son up from school, I smelled a smelled like antifreeze. I stopped at the store but I didn't think it was my car. About an hour later, when we went to church, I smelled the same smell, being we were the only car in the parking lot, I knew then it had to be my car. We put water in it and waited until the next morning to take to the dealership we purchased the car from. They said it appeared that I had hit something and the bottom of the radiator was damaged however I kept saying I didn't hit anything and they told me to try to turn it in to my insurance and see it they would cover it. One man even walked me to the car and said if I needed help that "help me out". That afternoon I was on the phone with the insurance company telling them exactly what the dealership said that I had to have hit something but I didn't remember hitting anything would they cover it. In the end the insurance company covered the repair of the radiator plus 5 days of rental car. When we went to have the repair done on the radiator, we asked for the old radiator back. My husband took it back to his shop and did a pressure test on it. The hole was actually in the middle of it not in the bottom and you could see where the fan shroud lined up where the radiator mounts to it and it had rubbed a hole in it causing this whole problem. Even though the insurance covered this, I still thought retribution needed to be made because perhaps this was a lemon car or either a recall needed to be done. This happened at 23,000 miles approximately. Then the following month the same fan shroud rubbed a hole in the air condition line and we were without air about 2,000 miles later and the dealership took responsibility for this and covered this under the warranty. It really didn't make any sense. I have called gmac and they have said the dealership are their eyes and ears and we have given them the old radiator back so they could see what we saw .

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Purchased new 2008 Aveo in April 2007 which has excessive vibration. I took into dealership and was advised it was due to the ac causing extra work for the motor. Since it was summer time I went on my way and dealt with this vibration (which only happens while in drive) it is now January and no ac is being used. I took the car back in to the dealership and was told yes there is excessive vibration and we will look into it 4 hours later they called to let me know they cannot find the problem and even contacted the gm advisors and are all in agreement with this issue however since there is not service bulletin or recall regarding this I will have to just deal with it and wait and see if something comes up with a fix. I cannot believe I am having to just deal with a brand new car with issues. . . This car has been taken in several times already. . Shifter locked up and would not move from park so they replaced that. . . Then car dies on hwy and was towed into the dealership had to fix something that had to do with the throttle, paint in now peeling and only has 11,000 miles any help would be great.

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