2002 Suzuki Aerio Service and Repair Manual

The Aerio arrived for 2002 as Suzuki's replacement for the Esteem, offered as S and GS sedans plus the taller SX five-door wagon. Every version used a 2.0-liter DOHC four-cylinder rated at 145 horsepower, paired with a five-speed manual or four-speed automatic, and all-wheel drive was not yet on the order sheet. This factory service and repair manual is written for that first-year car, with its original center-mounted gauge cluster and 2.0-liter engine, so the procedures, specifications, torque values, wiring diagrams and maintenance schedules match what is actually in your driveway rather than the later 2.3-liter cars.

Engines covered

• 2.0L inline-four — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 4-door wagon

Trims covered

• GS
• S
• SX

Known issues on the 2002 Aerio. Two recalls are on federal record: a windshield-mounting recall (FMVSS 212) because poor paint adhesion could leave the windshield insufficiently bonded to the body; a recall for five-speed manual cars whose shift-cable retaining clip could break when first gear was forced, disconnecting the shifter. NHTSA also logs 19 owner complaints, most often about service brakes and brake hydraulics. The manual's inspection procedures and specifications help confirm the affected parts are correct and secure.