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2004 Chevrolet Aveo

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Aveo.

Body PASSENGER CARTransmission Automatic 4-spd

The 2004 Chevrolet Aveo is a front-wheel-drive passenger car powered by a four-cylinder engine requiring 4.0 quarts of 5W-30 API oil, paired with a four-speed automatic transmission and achieving EPA fuel economy of 23 city, 31 highway, and 26 combined mpg. As the first model year in the Aveo’s 2004–2012 production run, this year logged 206 owner complaints—the second-highest total in the series—with the engine and engine cooling system being the most frequently cited trouble area, alongside two recalls. For researchers, the 2004 Aveo represents the model’s initial reliability baseline, marked by a higher-than-average complaint volume that underscores early powertrain and cooling concerns before later years saw fewer issues.

Model year2025 2024 2023 2021 2020 2019 2014 2013 2004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.0 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque81 ft-lbsOEM · verified

EPA fuel economy23/31/26 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 86 · 550 CCA battery, OE oil filter 12731175. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 86 · 550 CCAOEM · verified

Tire sizeP185/60R14OEM · verified

Wheel / rim5.5-J; 6-J inOEM · verified

OE service part numbers OEM · verified

Engine oil filter	12731175
Engine air filter	25199248
Spark plug	96130723
Battery	88866262 alt 88865315
Front wiper blades	96898048 alt 96898049
Serpentine belt	96183108
Thermostat	96143112 alt 96407677
Cabin air filter	96962173

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

Transmission

Automatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length	152.8 in
Overall width	65.7 in
Overall height	59.1 in
Wheelbase	97.6 in
Curb weight	2348 lb
Track (front / rear)	57.1 / 55.9 in
Weight distribution (front / rear)	63/37

Ratings & economy EPA / vPIC

EPA city / highway / combined	23 / 31 / 26 mpg
Drivetrain	Front-Wheel Drive
Passenger volume	77 cu ft
Cargo volume	12 cu ft
Recommended fuel	Regular Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Aveo of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

10.2–10.9 sec0–60 mph (tested)quickest 10.20 sec — 2004 LS 5-door Hatchback

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
2004	LS 5-door Hatchback 1.6L I-4	10.20 sec	17.40 sec	103 hp	FWD
2004	LS 5-door Hatchback 1.6L I-4	10.20 sec	17.60 sec	103 hp	FWD
2004	LS Sedan 1.6L I-4	10.40 sec	17.90 sec	103 hp	FWD
2004	LS 5-door Hatchback 1.6L I-4	10.90 sec	17.56 sec	103 hp	FWD
2007	LT Sedan 1.6L I-4	10.80 sec	18.10 sec	103 hp	FWD
2007	LT Sedan 1.6L I-4	11.80 sec	18.60 sec	103 hp	FWD
2009	5 2LT 5-door Hatchback 1.6L I-4	11.80 sec	16.00 sec	106 hp	FWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.0 qt of 5W-30 API engine oil, DOT 3 brake fluid. Torque lug nuts to 81 ft-lbs, the oil drain plug to 26.0 ft-lbs. The firing order is 1-3-4-2. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission Fluid	ATF
Automatic Transmission Fluid Capacity	6.2
Brake Fluid	DOT 3
Engine Coolant	DEX-COOL OR EQUIVALENT
Engine Oil	5W-30 · API
Engine Oil Capacity	4.0 qt
Manual Transmission Fluid	Synthetic · 75W-85 · GL-4
Manual Transmission Fluid Capacity	3.5-4.0

Engine torques

Intake Manifold to Engine Bolts	18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	18 ft-lbs
Engine Oil Pan Drain Plug	26.0 ft-lbs
Engine Valve Cover Bolts	7.4 ft-lbs

Chassis torques

Lug Nuts	81 ft-lbs
Front Wheel Hub	221 ft-lbs

Ignition

Cylinder Firing Order	1-3-4-2
Spark Plug Manufacturer	Woojin
Spark Plug Type	BKR6E-11
Spark Plug Gap	0.039-0.0.043 in
Spark Plug Torque	18.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.48 lbs
Oil Group	PAG
Oil Type	150
Oil Capacity	7.44 oz
Standard BCI Group Number	86
Standard BCI Cranking Performance	550 cca

Service checks

Pressure Test	17-23 psi
Radiator Cap Pressure Relief	17-23 psi
Thermostat Opening Temperature	189-216 °F
Injector Primary Resistance	11-14 @ 50-90 degreesF ohms
Engine Compression	100
Engine Compression	100 Minimum psi
Engine Compression	215 Nominal psi
Engine Compression	100 Minimum psi

Brakes

Brake Application	WITH 10 inch ROTOR / WITH 9 inch ROTOR
Torque Caliper to Bracket	20 ft-lbs / 70 ft-lbs
Torque to Knuckle	70 ft-lbs / 88 ft-lbs
Minimum Pad Thickness	0.080
Minimum Shoe Thickness	0.020
Brake Application	WITH 10 inch ROTOR / WITH 9 inch ROTOR
Rotor Max Parallel Variation	0.004 in
Rotor Runout Limit	0.001 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

70 ft. lbs., step2: 30 degrees, step 3: 15

70 ft. lbs

Cylinder Head — tightening sequence 4 stages

1	18 ft. lbs.	18 ft. lbs
2	70 degrees	70 degrees
3	70 degrees	70 degrees
4	50 degrees	50 degrees

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 mi	Accessory Drive Belt (inspect) · Cabin Air Filter (replace)
Every 30,000 mi	Brake Hydraulic System (drain, refill & bleed) · Clutch Hydraulic System (drain & refill) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Fuel Evaporative Emission Control System (inspect) · PCV System (inspect)
Every 60,000 mi	Spark Plug Wires (replace) · Timing Belt (replace)
Every 90,000 mi	Fuel Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

As the earliest model year in this federal record, the 2004 Chevrolet Aveo generated 206 complaints, 2 recalls, 2 investigations, and 409 TSBs. Complaint volume reached a generation peak of 235 in 2005 before trending broadly downward through 2012, placing 2004 below that high-water mark yet above the lower complaint counts recorded from 2008 onward. The 2004 model is one of only two years with investigations on record, sharing that distinction with 2005, and its two recalls tie the generation’s highest annual total, matched solely by 2007. Reported concern areas in 2004 were led by Engine & Engine Cooling with 52 complaints, followed by Electrical System, Air Bags, and Seat Belts, though the data does not specify underlying causes; the year also logged 23 crash-related and 9 fire-related complaints. Because 2004 combines elevated complaints with the generation’s tied-highest recall count and joint-highest investigation activity, it is a weaker choice within this generation, and buyers would be better served by 2008–2011 examples that show markedly lower complaint volumes and no investigations.

Open recalls

NHTSA campaigns

409

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

206

Owner complaints

23 involved a crash · 9 a fire

Owner complaints by model year NHTSA · this generation & adjacent

’04’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12

Owner complaints filed with NHTSA, by component

All 206 complaints on record, top 8 components.

Engine & Engine Cooling52

Electrical System23

Air Bags19

Seat Belts15

Engine12

Exterior Lighting9

Power Train9

Steering4

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 2 campaigns on record for this vehicle.

14V261000Exterior Lighting:HeadlightsReported 19/05/2014

General Motors is recalling certain model year 2004-2008 Chevrolet Aveo vehicles equipped with daytime running lights (DRL). In the affected vehicles, there may be heat generated within the DRL module located in the… Remedy: GM will notify owners, and dealers will install a revised DRL module, inspect the wiring connector for heat damage, and clean the DRL circuit grounds. Owners were sent interim…

04V407000Seat Belts:Rear/OtherReported 17/08/2004

ON CERTAIN PASSENGER VEHICLES, THE REAR SAFETY BELT CAN BECOME TWISTED. Remedy: DEALERS WILL INSTALL A SAFETY BELT WEBBING GUIDE TO PREVENT THE BELT FROM TWISTING. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438…

Technical service bulletins NHTSA · verified

Showing 5 of 409 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
PIP5601C	2025-07-18	Unknown Or Other	This PI communicates the requirement to provide a pico file to receive diagnostic…
PIT3271P	2024-09-06	Unknown Or Other	This Preliminary Information communication provides information to the technician about…
General Communication	2024-08-26	Electrical System	Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It…
24-NA-141	2024-07-24	Power Train	GM is receiving damaged (cracked or broken) transmission cores returned to the reman…
16-NA-383	2024-06-27	Fuel/Propulsion System	This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Aveo. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 86 battery Vehicles taking 4.0 qt Engine oil filter 12731175 Engine air filter 25199248 Spark plug 96130723 Battery 88866262

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2004 Aveo take?

4.0 qt of 5W-30 API, per the factory manual.

Does the 2004 Aveo have open recalls?

NHTSA lists 2 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Aveo get?

EPA figures are 23 city / 31 highway / 26 combined mpg.