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I won't buy anything else but chevy. But if anything happned the shroud warped causing it rub. That's the only thing that could have gone wrong. Because everything is tight fitting. The car has never been in a wreck. It has only been in the garage ( when my mother had the timing belt replaced) they stripped out the block so when we got the car I had to go into it and fix it put. New kit and re tgread and drill the holes in the idler bigger and bigger bolts. But that's it no front end work excet me puting projector lights into it and fog lights and that's it. But the only thing I can come to the conclusion of tge fan surroud warping. But that's it.
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My 2008, (hatch back, manual transmission, A/C) fan shroud bowed forward on the passenger side, contacting the radiator tubes, and rubbed holes in the radiator tubes.
I took out the fan shroud and the radiator. I put a straight edge on the passenger side of the fan shroud where it was contacting the radiator and it bows forward about 3/16" - 5mm.
My 2009 has more clearance between the radiator and fan shroud.
OG-Lou 25 yrs certified ACE master mechanic, retired.
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just a note - on my 07 hatchback i had the exact same issue.
a quick file of the offending area of the fan shroud took care of the issue as well. was about a 5 minute fix.
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I first thought of filing down the shroud but I thought the area was already thin and i didn't want to weaken the shroud. I would have had to remove over 1/4".
A friend had a similar problem but not as severe so he put 3 washers between the top of the shroud and radiator yoke. I didn't like the small contact area being so so I didn't go that route.
The heat gun and bending the shroud back to original seemed to be the strongest option. Yes it is more work but driving on gravel roads I need the strongest fix I can reasonably perform.
BTW, when I bought my Aveo, the dealer had 20 Aveos on the lot and this is the first they heard about the shroud warping or damaging the radiator. Yea, sure, I have a bridge I want to sell.
2008 Aveo, 5 door, 5 speed, no A/C
39MPG @65MPH, 4 studded snow tires on 1984 Dodge Caravan 4 Cyl-4 lug rims same specs including +- 2mm offset.
I take out the passenger and back seats, install my bed size 1/2" plywood board, sleeping pad, sleeping bag, and sleep in my car in a remote camping site that is 60 miles off a rural Hwy.
I also carry (seats removed) 16 ft long lumber and 600lbs of ready mix cement in my Aveo. Best car I ever owned and the car snobs give Aveo low marks. Their loss.
I see they are made in a car-pickup version for the southern part of Africa. I guess I missed out on what I truly needed.
