2004 Suzuki Aerio Service and Repair Manual

A bigger engine defines the 2004 Aerio: the 2.0-liter gave way to a 2.3-liter DOHC four-cylinder rated at 155 horsepower, and the sedan trims were renamed S and LX alongside the SX wagon. All-wheel drive remained available with the automatic. Because engine and trim details changed this year, parts and specifications from a 2002 or 2003 car will not always carry over. This factory service and repair manual follows the 2004 build, covering procedures, specifications, torque values, wiring diagrams, diagnostics and maintenance schedules for the 2.3-liter cars.

Engines covered

• 2.3L inline-four — DOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sedan
• 4-door wagon

Trims covered

• LX
• S
• SX

Known issues on the 2004 Aerio. One recall is on federal record: 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 14 owner complaints, most often about tires and suspension. The manual's inspection procedures and specifications help confirm the affected parts are correct and secure.