Originally Posted by
enflux75
drewd,
I just solved your exact same problem in my gf's car after about two years, same as you. Been lurking the forum for a while but I just finally solved this issue a few weeks ago.
Turned out it was the upstream 02 sensor. I figured this out only after buying a new Actron live data scanner with graphing, and trading cars with her so I could drive it to work every day to see the issue. The first 1.5 years it was doing it so intermittently, last 6 months it started doing worse. Had it to my local mechanic who was stumped, because it was not doing it that day.
I did mostly the same things you did too:
-New AC delco plugs and wires
-New Dorman air intake tube with sensor assy, original was ripped wide open
-Took throttle body off car and IAC and TPS off, cleaned, lubed, reassembled with new TB gasket.
None of this work I did CHANGED OR HELPED THE HOT RESTART STALLING IN ANY WAY. THE NEW UPSTREAM 02 SENSOR SOLVED IT 100%. I'm going to write up a more detailed post about it because I think alot of 2004 aveo's have this problem.
Basically your upstream 02 sensor is old and not heating up and responding to the ECU's switching fuel trims. I caught this during an OBD-II scanner recording session. The car was already warm, and the ECU went closed loop. BUT the 02 sensor stayed flatlined HIGH at about 0.78V, which is a rich fuel condition. In response the ECU start commanding the short term fuel trim lower and lower, down to -20% to -25%. Then the car would either stall on its own, or the ECU would switch back to open loop. I would have to shut the car off manually in neutral while rolling, restart it to force it open loop again, then drive off. By the time I drove off the exhaust gas would heat up the 02 sensor and it would run fine rest of day as long as I didn't shut it off again. So a long drive to the beach was no problem, but a short drive to the gas station, or store involving many hot restarts would make it buck, stall, feel like the throttle cable was made of a rubber band.
NONE OF THIS STALLING OR SLOW 02 RESPONSE EVER GAVE ANY CODE OR CHECK ENGINE LIGHT OF ANY KIND. IN OVER TWO YEARS. EVEN WHEN THE PROBLEM GOT MUCH WORSE.
I believe the 2004 Aveo ECU firmware does not properly respond to a long 02 sensor response time. I have a feeling if I had gotten my ECU reflashed at the dealer, the check engine light would have come on. My gf bought this car new in 2003, so I know the history and it is the original firmware in the ECU as far has I know.
Hope this helps sorry for long post.