$\cos \theta = \frac{av}{|a||v|}$ (1) (from dot product)
$\cos \theta = \frac{|a_v|}{|a|}$ (2) (from cosine definition)
combining (1) and (2):
$\frac{av}{|a||v|} = \frac{|a_v|}{|a|}$, so $av = |a_v||v|$ (3)
but
$a_v v = |a_v||v|\cos0=|a_v||v|$ (4) (by dot product)
now if combine (3) and (4), I have:
$av=a_vv$ and $a = a_v$ which is false by assumption.
What's wrong? There must be some obvious explanation, but I checked it multiple times and can't see it.