SuzukiAerio2002Overview/suzuki/aerio/2002/base/

2002 Suzuki Aerio

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Aerio.

Body PASSENGER CARTransmission Automatic 4-spd

The 2002 Suzuki Aerio is a passenger car featuring an automatic 4-speed transmission and EPA fuel economy ratings of 23 city, 28 highway, and 25 combined mpg. Within the Aerio's six-year model run from 2002 to 2007, the 2002 model recorded 19 owner complaints—a figure that positions it between the model's peak complaint year of 2003 (36 complaints) and its lowest complaint year of 2007 (3 complaints). The most frequently cited issue for this model year centered on service brakes and hydraulic system concerns, and the vehicle was subject to two recalls during its production run. This complaint profile places the 2002 Aerio in the middle of its model's reliability trajectory, suggesting neither exceptional durability nor significant mechanical concerns compared to other model years in the lineup.

Model year20072006200420032002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Lug nut torque62 ft-lbsOEM · verified
EPA fuel economy23/28/25 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

Tail / brake / turnBRAKEOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length166.5 in
Overall width66.5 in
Overall height61 in
Wheelbase97.6 in
Curb weight2635 lb
Track (front / rear)57.1 / 55.9 in
Weight distribution (front / rear)61/39

Ratings & economy EPA / vPIC

EPA city / highway / combined23 / 28 / 25 mpg
DrivetrainFront-Wheel Drive
Passenger volume90 cu ft
Cargo volume15 cu ft
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

Torque lug nuts to 62 ft-lbs. The firing order is 1-3-4-2.

Lubricants & capacities

Engine CoolantETHYLENE GLYCOL
Power Steering FluidATF

Chassis torques

Lug Nuts62 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Spark Plug ManufacturerNGK
Spark Plug Gap0.040 in
Spark Plug Torque15.0 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.10 lbs
Oil GroupPAG
Oil TypeND 8 oil
Oil Capacity8.43 oz

Service checks

Pressure Test16 psi
Radiator Cap Pressure Relief16 psi
Thermostat Opening Temperature176-183 °F

Brakes

Torque Caliper to Bracket25.5 ft-lbs
Torque to Knuckle61.5 ft-lbs
Minimum Pad Thickness0.031 in
Minimum Shoe Thickness0.040 in
Rotor Runout Limit0.004 in
Rotor Minimum Machining0.79 in
Rotor Finish0.71 μin
Drum Maximum Machining7.87 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 5 stages
138.5 ft. lbs.38.5 ft. lbs
261 ft. lbs.61 ft. lbs
3Loosen all bolts.
438.5 ft. lbs.38.5 ft. lbs
576

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 30,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

At 7,500 miFinal Drive (drain & refill)
Every 7,500 miBrake Drum Assembly (inspect) · Engine Oil (drain & refill) · Engine Oil Filter (replace)
Every 30,000 miEngine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Final Drive (inspect fluid level) · Spark Plugs (replace)
Every 60,000 miBrake Hydraulic System (drain, refill & bleed)
At 105,000 miTransmission Assembly (drain & refill)
At 120,000 miFuel Evaporative Canister (replace) · Fuel Evaporative Canister Filter (replace) · Fuel Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2002 Aerio debuted with 19 complaints, two recalls, and 14 technical service bulletins — a moderate complaint count that sits well below the 36 filed for 2003 and the 22–27 range seen in 2005–2006, though above the 14 in 2004 and the minimal figures for the final 2007 model year. Recalls held at two for both 2002 and 2003 before dropping to one annually through 2006 and zero in 2007, while TSBs declined steadily from 14 in the first two years to just three by the end of the generation. The leading complaint categories for 2002 were service brakes (hydraulic) and suspension at four each, followed by power train and engine cooling at two apiece; the data also records two crash-related complaints and one fire complaint for the target year, though root causes are not specified. As the launch model year, 2002 reflects typical early-production variability but avoids the complaint spike that defines 2003 and the secondary peak in the mid-cycle years. For a buyer prioritizing federal complaint volume, the 2002 is a stronger candidate than 2003, 2005, or 2006, though the elevated TSB count suggests thorough dealer follow-up on early issues is advisable.

2
Open recalls
NHTSA campaigns
14
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
19
Owner complaints
2 involved a crash · 1 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 19 complaints on record, top 8 components.

Service Brakes, Hydraulic4
Suspension4
Power Train2
Engine & Engine Cooling2
Fuel System, Gasoline2
Engine & Engine Cooling,Structure1
Electrical System,Structure,Latches/Locks/Linkages1
Tires1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 2 campaigns on record for this vehicle.

03V223000Visibility:WindshieldReported 16/06/2003

CERTAIN PASSENGER (111 MY 2002 ESTEEM, 777 MY 2002 AERIO, 2,368 MY 2003 AERIO) AND SPORT UTILITY (324 MY 2002 GRAND VITARA, 274 MY 2003 GRAND VITARA, 684 MY 2002 GRAND VITARA XL-7, AND 781 MY 2003 GRAND VITARA XL-7)… Remedy: DEALERS WILL INSPECT THESE VEHICLES. VEHICLES THAT ARE FOUND TO HAVE INSUFFICIENT PAINT ADHESION WILL EITHER HAVE THE PROBLEM REMEDIED BY REPAINTING, OR WILL BE REPLACED, OR…

07V307000Power Train:Manual TransmissionReported 15/07/2007

ON CERTAIN VEHICLES EQUIPPED WITH 5-SPEED MANUAL TRANSMISSIONS, DUE TO IMPROPER SHAPE OF THE CLIP, THE RETAINING CLIP THAT KEEPS THE GEAR SHIFT CABLE ATTACHED TO THE GEAR SHIFT LEVER CAN CONTACT THE GEAR SHIFT LEVER… Remedy: DEALERS WILL REPLACE THE GEAR SHIFT CABLE RETAINING CLIP WITH A CLIP THAT HAS A DIFFERENT SHAPE. THE RECALL BEGAN ON AUGUST 13, 2007. OWNERS MAY CONTACT AMERICAN SUZUKI AT…

Technical service bulletins NHTSA · verified

Showing 5 of 14 bulletins on record with NHTSA.

BulletinDateComponentSummary
SUZ_0160082022-07-08SuspensionReminder of the importance to conduct safety inspections for rust damage to suspension…
N-Q-G-0452018-11-20SuspensionThis Service Bulletin was sent by Suzuki Motor Corporation to its authorized Suzuki…
TSB-05-042892009-05-01Power TrainSUZUKI: PARTS LIST FOR REPAIRING MANUAL TRANSAXLE 5TH GEAR CONCERNS SUCH AS POPPING OUT…
02050742004-01-01Service Brakes, HydraulicAERIO FRONT BRAKE PAD. ALSO INCLUDES 2004 MODEL. *MJ
04051742004-01-01Electrical SystemINSTRUMENT CLUSTER BULB REPLACEMENT. ALSO INCLUDES 2004 MODEL. *MJ

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Aerio. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

Does the 2002 Aerio have open recalls?

NHTSA lists 2 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Aerio get?

EPA figures are 23 city / 28 highway / 25 combined mpg.