The contact owns a 2005 Chevrolet Aveo. The contact stated that the engine overheated and the temperature gage display stated that the vehicle was overheating. The failure recurred on several occasions. The vehicle was taken to an independent mechanic where it was diagnosed that the drl module needed to be replaced. The contact received a notification for NHTSA campaign id number: 14V261000 (exterior lighting), however the part needed to perform the recall repair was unavailable. The manufacturer was notified of the failure. The approximate failure mileage was 32,000.

- Lancaster , PA, USA

Timing belt failed. Destroying the heads and pistons...updated 07-05-13

- High Point, NC, USA

Coming home from work, dash lights got brighter, airbag light stayed on, car tried to stall around a corner when brakes were pressed. Took in for service, had alternator and battery replaced, also serpentine belt. This was 4 months ago. Problem was not fixed, just made it less severe. Since that time, when you hit the brakes the headlights dim. The dash clock comes on and off randomly, the airbag light is on all the time. When it is cold (the car, not the weather), the transmission has a hard time shifting. As of this morning it will not start. Am going to have it looked at tomorrow morning, but do not have high hopes. Bought car in 2006 with 8,000 miles on it, have had shift lock assembly replaced, wheel bearings, battery, alternator, serpentine belt. Probably other things I cannot think of right now. The electrical problem worries me though.

- Hamilton, MI, USA

2005 Aveo (bought new) with timing belt failure destroying engine. Had this happened on the interstate at 70 miles an hour it could have been fatal. From my research GMC has known about this issue since at least 2006 and yet have not assisted consumers to correct this nor recalled their car. I have read reports on almost all years of Aveo having this problem well before the 60000 recommended timing belt replacement. Two different mechanics confirmed timing belt failure. All I get from GMC is the run around. Upset over money but more concerned about these cars being on the highways and creating some horrible accident when the engine suddenly stops working and controlling the car is difficult or impossible. Planning to get rid of mine, can't afford the thousands of dollars to fix nor do I trust this car.

- Warrenton, MO, USA

Thermostat housing has cracked due to its unreliable plastic composition. After failure, coolant was leaked throughout engine compartment creating a major fire hazard and causing damage to multiple engine components. After researching this problem, numerous complaints were discovered with the exact nature.

- Metairie, LA, USA

2005 Chevrolet Aveo. Consumer writes in regards to timing belt failure the consumer stated while driving 70 mph, the vehicle suddenly stopped running, it felt as though the transmission had fallen out. While trying to get to the emergency lane, the vehicle would not accelerate. Upon inspection, it was determined the timing belt idle pulley had broken, along with the serpentine belt, thermostat, water pump, as well as all of the 16 valves were bent. The total cost in parts and labor was $ $2,914.54. The consumer also stated the door lock cylinder fell into the door panel, the vacuum supply line to the sensor was cracked, which caused a vacuum leak.

- Glendale, AZ, USA

The contact owns a 2005 Chevrolet Aveo. The contact stated that the timing belt gear was fractured on one side and the other side was close to failing. The timing belt was replaced twice prior to the most recent failure by a local mechanic, but the failure recurred. Neither the dealer nor the manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was 74,000 and the current mileage was 126,096.

- Wilmington, IN, USA

Was enroute to work in 2005 Chevrolet Aveo when the timing gear pulley broke on the motor. The engine was destroyed as I found out later. 5 or 6 weeks earlier I had just had the timing belt replaced. I had it replaced before factory reccomendations. My mechanic told me then I needed to have it changed. The belt did not break to cause engine failure. A cheap plastic pulley broke instead. When the pulley broke the timing belt went limp and the engine decided to deposit some valves through 1 piston. This to me is a safety concern since it was all I could do to get the car off the interstate. Chevrolet knows about these problems and they dont seem to care. I dont think this vehicle should be allowed to be sold.

- Bessemer City, NC, USA

The previous evening we were coming home from visiting some friends, the car was never over 100 miles day we bought it until the time of the engine's demise, we noticed a slight clicking noise over the music of the radio, pulling into a lighted area, we found all fluids fine, no dripping, no heating up, no stalling, no real indications of any trouble except a slight clicking.. the next morning I noticed a clicking at start up, immediately I drove off to the repair shop that was just blocks away, when I was within 1 block of the shop the entire system shut down, we were forced to get a wrecker to tow us the last block. The independent repairman informed us this was a common problem with this make of auto (Aveo) due to a design defect with the timing belt, it would destroy the engine and he could not find a replacement engine. Because we had 75 thousand miles on the car, (and it is paid off) he thought he had heard of a recall in 2006, he suggested we contacted the auto dealer, auto way Chevrolet, hwy 19, clearwater, fla. Which we did. We were informed by their service director that they could not find an open 2006 recall, though a reminder to replace belt at 68 K, no alert nor advisory was ever received though we do get all advertisements and she advised awc did not handle such a problem, but, they would give us GM's number, upon calling that number I talked with a very amiable young man in buenos aires, who also informed me they did not appear to have a recall on this particular model, he then called auto way Chevrolet, clw. Fla, usa and monitored the service department now telling me if I would bring it to them, they could evaluate the cause and maybe work something out with us.. upon internet investigation we have found a number of individuals complaining about this year, of Aveo, having the engine fail in roughly the same mileage 68-78 thousand miles..

- Tampa, FL, USA

2005 Aveo 63,000 this Aveo quit pulling out from the turnpike booth on pa.43. It was towed to fike Chevrolet where I was told the timing tensioner pull split in half throwing the timing belt off. Since this is a interference engine ( meaning without the timing belt the valves hit the pistons) it causes a catastrophic failure to the cylinder head and possible piston damage. The dealer salvage yards and most other mechanics admit this is a defect in the plastic pulleys and timing belt. GM says (it happens to all of them ) and will not compensate for damages. I ask GM if they recorded my conversation and they do but will not allow me a copy because it's for (internal use only) this Aveo had it's timing belt and head replaced at 11,400 mile and at the current mileage is under the mileage for recommended replacement. Front wheel bearing also where replace 4 months ago. This was the first and last GM product I will ever buy.

- Latrobe, PA, USA

Cracked thermostat housing- cheaply made (plastic) thermostat housing which can easily crack and it has in several Aveo between the years 2004-2006. I have a 2005 Chevy Aveo and it cracked costing me entirely too much money on a tow, rental car etc.

- Stockbridge, GA, USA

The contact owns a 2005 Chevrolet Aveo. The contact was driving approximately 40-45 mph when a knocking was heard from the engine. The contact removed the vehicle from the roadway and shut the vehicle off but the vehicle failed to restart. The vehicle was then towed to a local repair shop where she was advised that there were damages to the engine valves and that the head would need to be removed. The mechanic also recommended taking the vehicle to an authorized dealer. The vehicle was not taken to a dealer. She contacted the manufacturer and they advised her that they could not provide any assistance until the vehicle was inspected by an authorized dealer. The vehicle was not repaired. The VIN was unavailable. The approximate failure mileage was 78,000.

- Beauford, GA, USA

The timing belt idler pulley broke, my timing belt is stripped, and my valves are bent on my 2005 Chevy Aveo. It has 58,872 miles. I bought it less than 8 weeks ago. GM is not being cooperative.

- Prosper, TX, USA

I have a 2005 Chevrolet Aveo with 50,000 miles. I have done the routine maintenance on the vehicle. However, a week ago the timing belt broke and ruined my engine. In my maintenance book it says not to change the belt until 60,000 miles and GM is telling me it is my problem since I am no longer under warranty. I have looked on line and found others who have problems with their timing belts going before the required maintenance. Can you please help. They want $2,200 to fix vehicle. This occurred while I was driving and I lost power in my car while gliding through a red light. Thank god no one hit me. Updated IVOQ 02/02/11

- Edison, NJ, USA

Was driving to work and went through a drive through for coffee. Noticed that while idle, my car started to over heat. Continued on to work approx 1 mile down the road. When I got there I opened the hood and found that a hose was no longer connected to the thermostat housing. Then I noticed that the plastic housing itself was cracked in half and hanging off the car. It cost me about $80 for a replacement metal part which I had installed by a friend. This happened during the summer 2010; car had approx 51,000 miles. It is now December 2010, and car has approx 56,00 miles. My check engine light is on and I brought the car to a car part store to have them check the code. Apparently now I have to replace the oxygen sensor, which costs about $150 + labor. I bought this car used in 2007 and still have about 2 years left to pay on it. The warranty is no longer good.

- Fall River, MA, USA

Busted timing belt pulley after only 46K miles. Busted all 16 valves. Required a complete head job at over 2K$.

- Pascagoula, MS, USA

My wife was driving to the grocery store about a mile away in a 2005 Chevy Aveo. When she got there smoke was pouring out of her hood. Upon further inspection, the (plastic) thermostat housing was split in half allowing all the radiator fluid to spill out. After further research, this has been a widespread problem on this car and the manufacturer has even switched to using aluminum thermostat housings instead of the plastic ones without posting a recall. If she had been driving more than a mile down the road, it is very possible her engine would have over heated and possibly warped the heads and destroyed her engine. This known problem needs to be a recall.

- Oviedo, FL, USA

The contact owns a 2005 Chevrolet Aveo. The contact stated the vehicle overheated as a result of the thermostat casing melting. The dealer stated the casing was melted because it was manufactured from of plastic. There was not a recall for the failure however the dealer advised that the design had recently changed on the casing from plastic to metal. The failure and current mileage was 85,000. Updated 11/16/10.

- Washington Courthouse, OH, USA

I was running errands when steam came gushing out on my passenger side in the hood area. I pulled over to discover that my thermostat housing was broken and my thermostat laying elsewhere in the car. I searched the internet and discovered that this is a well-known problem. The current thermostat housing is made of plastic. The design is such that the only thing that was holding the thermostat in was a sound welded plastic seam. I have ordered a new metal housing with an improved design. To me, this indicates Chevy knew about this problem. Called Chevy consumer line and they gave the old line of your car is not under warranty and claimed they had no history of complaints.

- Winsted, CT, USA

I have just over48,000 thousand miles on my 2005 Chevy Aveo hatchback. The thermostat housing unit on this vehicle is made out of plastic. Over time it will wear down, and eventually crack. As a result, the engine coolant will leak out and your engine will overheat. It is not part of the power train warranty coverage and with tax the repair ran $312 dollars. This is for a design issue with using hardware with a plastic housing. The dealership knows this issue exists and that you'll have to come in for repairs eventually. Luckily I wasn't on the freeway when this happened and traveling at low enough speeds to make it home safely. I then had the car towed to the dealership for repairs. The automotive representative advised there wasn't any real way to avoid the incident with any preventive maintenance. I said it was nothing that I did with the use of the vehicle. It was a matter of timing, the summer heat conditions and the fact that the original thermostat component has a plastic housing. He stated it should not happen again as the replacement thermostat was of different construct and was no longer plastic.

- Houston, TX, USA