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Suzuki Aerio Maintenance and Repair



  • I have an 06 SX. The Passenger side rear tire wore on the inside. I asked my mechanic to research for a TSB and he found it. It is for 04 - 06 SX. There are serial numbers on it so beware, there are not many which I found strange. My serial # was 2 off from the TSB. MY Suzuki Dealer was a little reluctant but called the factory rep for me. They are performing the TSB no charge. The TSB # is TS 05 11225, date of issue is 11/22/2005. There is a part required for the AWD cars, part #27610-54G00. It is the Viscous Coupling, but the dealer said they are replacing the entire rear drive shaft! The 2 wd requires the Rear Control Rod Assy part # 46300-60G21. There is a new Alignment for the rear, all models.

    Hope this helps for anyone who has an isue wth Rear Tire premature wear.
  • bob_mbob_m Posts: 2
    Out of the blue, my right front window will not raise. I have a 2003 Aerio SX staight stick. All the other windows work OK. What gives? Help!
  • bob_mbob_m Posts: 2
    Never mind! I must have pressed the window disable switch. You can tell how much I use that switch. Live and learn.
  • carthellcarthell Posts: 128
    I don't think the window lock switch on the driver's side affects anything but the rear windows. I'll check my unit tomorrow.
  • I have a 2003 Suzuki Aerio SX wagon. Up until now we have had no big problems with it. Its a 4 banger automatic with 76,500 miles on the odometer. Its been well maintained and cared for. However, the other day the A/C started doing something strange, the driver side is blowing warm air and the passenger side is blowing cold. I called my local dealership and spoke with an advisor but that was certainly a joke! He tells me that there is no way that could be happening because it the air all comes thru the same hose whether its coming from the heater core or the a/c! Any help on what this might be or what it might take to fix it would greatly be appreciated!
  • I have the same exact problem and have no clue, someone told me it might be moved cuz I had remote starter and alarm installed.
  • dkarasindkarasin Posts: 10
    I have a similar post see #346. I bet that you will also have a problem with the heat doing the same thing the side that now blows cold air will blow hot when the heat is on and the side blowing hot will blow cold. I took the car to two different dealers near me spending ~$400 at each. Neither dealer could fix it. I have a theory that one of the vent doors either broke or is out of place. The side that does not work is just blowing outside air into the compartment. In my area (upstate NY) the problem is worse in the winter. I had access to a 4 channel temperature logger and took data on the trip home from work to prove the problem to the first dealer. I complined to Suzuki America and got no help. I was told by them "sir your car has heat".

    If you have comprehensive insurance your best bet will be to hit a deer and total the car.

    One more note. I have not been able to drive my `03 SX since 1/6/09 when the engine died.(92k miles and still under warranty). I took it to the dealer, they agreed by the sound that the engine was bad and told me they needed ~$300 to pull the pan and head to take pictures for Suzuki for authorization of the engine replacement. I knew then that I was going to get screwed. They told me the engine was bad and that I ran it out of oil, which of course is not true. After the dealer threatend to start charging storage I towed the car home and got a better look at it with a few car friends. Neithe the dealer or Suzuki would say more than the motor was bad. We found that the skirt on the #3 piston was broken and a stationary cam chain guide was broken. I don't see even if the car was run low on oil how it could cause either problem. Suzuki still asserts that it is my problem.

    Suzuki will act in bad faith every time. Get rid of your problem car as soon as you can it will only get worse. :lemon: :lemon: :lemon:
  • I have an 05 that is overheating only when it is idling. If I am driving it down the street there is no problem. Change the thermostat already and did not take care of the problem. Does anyone have any suggestions?? I am stumped here.

    Thank you
  • angel,

    It seems likely that your electric fan is not coming on for one reason or another. It could be something as simple as a fuse or relay, or it could be that the fan itself is out.
  • moopitzmoopitz Posts: 1
    I have an 03 aerio sx and i love it. I would not trade it for anything. in fact I am researching the best aftermarket clutch to put in. I am leaning towards a stage 2. It currently has a cold air induction and custom exhaust. I lucked out and had minor gear work done by my local suzuki mechanic in which he didn't properly seal the tranny and I ended up with a new transmission at 98,000 miles for free!!! I also had a timing chain snap and the valves bent, but suzuki honored the warranty again and re-did the engine. Only issue i have is the clock light not working. nothing to lose sleep over. Any suggestions on the Stage 2 Clutch would be appreciated though. Oh, I love the way it handles the road too. ;)
  • just so everyone knows i know nothing about cars and probably way over pay people for maintenance. that being said, my car does go in for regular oil changes, tuneups, etc. i have a 2003 aerio sx awd automatic with ~78k miles. i've been fairly lucky and really only had the minor "annoying" issues mentioned in the forum - rattling (heat shield which apparently we don't even really need) and the annoying clock light issue. actually that has somewhat migrated to a larger part of my panel lights - sometimes only half work and sometimes they all work. it's annoying but i can live with it.

    just wondering if anyone has had to replace anything related to their exhaust. i apparently need a "muffler and center pipe assembly" since there are rust issues. according to suzuki they have to order this part from california and parts alone cost about $575. a muffler place nearby has the muffler for $200ish but they are missing the center pipe. the auto shop that would fix it would charge under $100 labor so the bulk of the cost to fix this is parts. any ideas where i can find the parts? and/or has anyone one else had this problem?
  • jaltfunjaltfun Posts: 8
    Well, as most of you probably already know, Suzuki dealships are dropping like flies. I purchased a new Aerio Premium 2 wheel drive in 2005. It has been a good little car and currently has a little north of 68,000 miles on it. A couple of little zingers but after a lot of urging on my part, the dealer took care of them. When I took it back to the local dealer because one of the windshield washer nozels quit working, it took several phone calls and finally some good old fashiond yelling to get them to replace it.

    Three weeks ago, I had a BIG zinger. The engine quit on my sister in law as she was driving home. She called and told me there was a loud "bang" and she couldn't get it started. Since she was about 2 hours away, I suggested she have it towed to the local dealer.

    The Gainesville, Florida Suzuki dealership is no more and we were told to take it to a Chevy dealership. They had the car for about three days and the report they gave us was bad, real bad. The head was warped and the crankcase was full of coolant. A rod broke in two putting a rather impressive hole in the side of the block. The coolant was not low as I had just checked all the fluids before I let her use the car earlier that day.

    Three weeks later we have a brand new engine and a new 100,000 mile power train warranty, and, get money out of pocket. :)
  • jaltfunjaltfun Posts: 8
    Here is what I would do. Take it to a muffler shop. Not one of those big name chains. There is probably one near you. Have them look at it. They keep pipe in all diameters and mufflers are a dime a dozen. As long as your catalitic converter isn't damaged, they can cut out the old stuff, bend and weld in new stuff and have you back on the road for around $200.00. If you are young and crazy, you can get one of those big fat chrome mufflers for about $50.00 more.
  • Thanks for the advice jaltfun!
  • Hi,

    First of all thank You very much for every one who are giving suggestions and those who are sharing their thoughts.

    I Bought second hand suziki aerio 2003 model 3 months back. it worked fine till now and we went for a long drive 2 months ago too but did not have a problem. But suddenly yesterday when I was on highway suddenly car started to jump and all of sudden after some distance it stopped. It was not moving at all. I stopped the engine and again started it but the car did not move forward. And when I start the engine and leave it in parking it shuts down by itself. I took to the mechanic he saw it and told nothing except take to the dealer.

    I am not understanding what to do. Please can anyone suggest some suggestions....

    Thanks in Advance.
  • I am assuming that you have an automatic, but it really doesn't matter. Something in your transmission has stripped, or the CV joints have gone out, though that is less likely. The CV joint fix is fairly cheap, but the transmission fix is going to be a big hitter, and probably can only be done by a dealer. Good luck.
  • Sounds ridiculous, but check and if necessary, try adding TRANSMISSION oil. After some major check up when they were supposed to drain and change the transmission oil on my car, I had some sort of problem with the car popping out of gear - I'm an automatic - that was the trouble. I was off the stick and had to added over two quarts of transmission fluid. Multiple voice mails to the dealer in San Jose, CA and multiple voice mails to my service manager, but no call backs. Needless to say, I never went back. :cry:
  • 2006 Aerio - Left headlight very dim , with blue warning symbol on dash . I changed bulb and checked fuse - was ok . What's next ?
  • I purchased an 04 Aerio wagon which has no manual. I am wodering about replacement of headgasket and timing belt/chain. Ihave 160,000 k's on car. Thanks in advance for any info
  • I'm just wondering what became of this. I too own an '05 Aerio and I am completely appalled at the problems I'm experiencing. At 76,000 kms, the car is on it's 3rd set of tires (and not cheap ones), on it's second set of front brakes and rotors (and need to be replaced again), the steering rack is leaking and all four struts are shot.
    Is this vehicle on par with the Ford Edsel???
    I was joined to suzuki at the hip until this piece of crap came on the market. Never again.
    I got an '05 swift at the same time (which is made by Daewoo), and it has 93,000 kms. I just got the second set of tires this past summer and still on the original brakes and rotors. A better vehicle by far.
  • I have a 2005 Aerio and had to change the tires at 35,000 miles. I rotate my tires at each oil change and consistantly get 60,000 to 70,000 miles on other cars. I'm still on the original brakes though. :(
  • mcgjapanmcgjapan Posts: 1
    my engine light is on and i was also told to get a new catalytic converter. but for only 350.
  • I don't know if this is the same issue or not.Skip to the bottom paragraph if you are in a hurry.

    I had a problem with my check engine light. I asked one of the guys at work, and was sent to their "favorite" mechanic: I had the code checked; it indicated I needed a new catalytic converter ( smog equipment). In my case, the location of the code indicated the expensive $1000 (or was it two thousand?) one. He recommended I had tried pouring in a container (quart? It the size of a lighter fluid bottle-the ones people use on their BBQ) of denatured alcohol in the gas tank to see if that would clear it( when you do the fill up); no luck. The mechanic also tried to just reset the code, and told me if the code/light came back in, then I would probably have to do it. The light came back in.

    I was panicked at the $$$$ outlay in my future...THEN, it was suggested, I start inexpensively, and tried to JUST REPLACE THE SENSOR, which was like $79. The local mechanic who did the work even told me, upon pickup ,that the original sensor tested good. The codes cleared and never came back, and that was a year and a half ago! Oh, and you know if you fail to tighten the gas cap well enough, the check engine light comes on, don't you? It will clear in a couple of start-ups after you tighten it. ;) Good Luck. Ronnie :blush:
  • I've got a '03 Aerio SX that 'requires' 195/55/15 tires. Does anyone know if you can put a 195/65/15 on the rim and have enough clearance in the wheel well?

    I know that the 65 is 10% larger, but it's also cheaper and has a higher milage guaruntee. Not to concerned with the difference in speed ratings 'cause I don't race it or drive over 75mph.
  • I also have the Aerio SX 03 model, and a 215/50/15 is 0.1% larger in diameter than the 195/55/15 stock tire. Under a really hard turn, you can create some contact with the front tires, but it is not even visible on the front tires. It helps stabilize the rear end and decreases wheel spin under hard acceleration in first gear. I suspect that it costs a tiny bit in gas mileage, but the difference is really tine. If you wish to know the difference between two tire sizes in the p-metric system, go to this java tire calculator:
  • Hiya,

    I own a 2005 Aerio Sx, with 69,xxx miles, which seems to enjoy stalling while in reverse (when shifted from park) and has a rough idle. Oddly enough, the issue seems to be alleviated when the AC is on. Any ideas as to what is going wrong?

    Thanks :-)
  • Hi, my husband was a mechanic for many years. He says that for part of your answer, the not stalling when the A/C is on, is because the idle increases when the A/C is on. He says, and as I think you already know, the bigger question is why is the car idling rough?
    Mine idles rough when I am low on oil or in need of an oil change, which is usually the same. Meaning, when I am in need of an oil change, I am also low on oil for some reason. This has been going on since I was in the 60,000 mile range or before even. I have a 2003 Suzuki SX. Ronnie
  • The car has a leak I tried to add leak detector and 134a but the pressure is to LOW HOW DO YOU BY PASS THE LOW PRESSURE switch and Where is it Located ???
  • I have 83,000 miles on my 2006 SX4. I took it to my mechanic and he told me it sounded like piston slap when cold. I took it to Suzuki and they agreed. They reviewed all of my maintenance records ,looked inside the oil pan and found it clean so agreed to a Short block under warranty. Now I believe I have what I would refer to as detonation or Knocking. The dealer said it is normal but admits they hear the noise. Now I am waiting on the District rep to visit. This all less than 1,000 miles since the short Block was installed.

    Anyone know of ECU updates or failed Knock Sensors...? Any other experiences with a noise when cold over 2500 RPM? Change the Spark Plug to colder or Hotter plugs? This is my daily driver and I do or have the mantenance done and check the book for each mileage as described. I disagree with changing Anti freeze every 30,000 but I do it;).

  • dlbennettdlbennett Posts: 1
    I have a 2003 Suzuki Aerio and love it... however, now that we are in the summer months I use my air conditioner more often or always. When the air conditioner is on and I am sitting at a red light there is a loud squeeling sound. This sound stops when I accelerate or put it in neutral or park. Does anyone know what I should have checked out?
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