SuzukiAerio2004Overview/suzuki/aerio/2004/base/

2004 Suzuki Aerio

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Aerio.

Body PASSENGER CARTransmission Automatic 4-spd

The 2004 Suzuki Aerio is a passenger car equipped with a four-speed automatic transmission and EPA fuel economy ratings of 22 city, 28 highway, and 24 combined mpg. Owner-reported data shows 14 total complaints for the model year, with tires identified as the leading concern and a single recall issued. Across the 20022007 production run, complaint volumes peaked at 36 in 2003 before declining to a low of 3 in 2007, placing the 2004 model in a transitional period of improving reliability. This trajectory indicates that the 2004 Aerio benefits from early running changes but still sits above the model's best-year complaint levels.

Model year20072006200420032002

Quick specs

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

Lug nut torque62 ft-lbsOEM · verified
EPA fuel economy22/28/24 mpgEPA · verified

Fitment & sizes

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

Tail / brake / turnTAILOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length171.3 in
Overall width67.7 in
Overall height61 in
Wheelbase97.6 in
Curb weight2875 lb
Track (front / rear)56.7 / 56.7 in
Weight distribution (front / rear)62/38

Ratings & economy EPA / vPIC

EPA city / highway / combined22 / 28 / 24 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

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity4.8
Engine CoolantETHYLENE GLYCOL
Manual Transmission Fluid75W-85 · 75W-90 · GL-4
Manual Transmission Fluid Capacity4.9
Power Steering FluidATF

Chassis torques

Lug Nuts62 ft-lbs
Transfer Case Fill Plug17.0 ft-lbs
Transfer Case Drain Plug17.0 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Spark Plug ManufacturerNGK
Spark Plug Gap0.039-0.0.043 in
Spark Plug Torque18.0 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 60,000 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 miDrive Axle Assembly (drain & refill)
Every 7,500 miAxle Shaft Oil Seal (inspect) · Brake Drum Assembly (inspect) · Brake Line (inspect) · Brake Linings (inspect) · CV Joint Boot (inspect) · Engine Oil (drain & refill)
Every 15,000 miBrake Pedal Assembly (inspect) · Engine Coolant System Hoses (inspect) · Fuel Line (inspect) · Fuel Tank (inspect) · Fuel Tank Filler Cap (inspect)
Every 30,000 miAccessory Drive Belt (inspect) · Differential (inspect fluid level) · Engine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Exhaust System (Complete) (inspect) · Ignition Coil (inspect)
Every 60,000 miSpark Plugs (replace) · Transfer Case Assembly (drain & refill)
At 120,000 miBrake Hydraulic System (drain, refill & bleed) · 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 2004 Suzuki Aerio represents a notable dip in reported issues compared to the earlier years of its generation. While complaints peaked at 36 in 2003, the 2004 model saw a reduction to 14 complaints and a decrease in Technical Service Bulletins (TSBs) from 14 to 9. For 2004, the most frequent complaints centered on tires (4) and the power train (2), though the data does not specify the root causes of these issues. This year sits at the beginning of a general downward trend in complaints and TSBs that continues through 2007, with recalls remaining consistently low across the arc. Because it has fewer complaints and TSBs than the 2002, 2003, 2005, and 2006 models, the 2004 Suzuki Aerio is a good year to buy.

1
Open recalls
NHTSA campaigns
9
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
14
Owner complaints
3 involved a crash · 0 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 14 complaints on record, top 8 components.

Tires4
Power Train2
Unknown Or Other1
Electronic Stability Control (Esc)1
Equipment1
Electrical System1
Suspension,Service Brakes, Hydraulic,Exterior Lighting,Visibility,Seat Belts,Tires1
Suspension,Tires1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 1 of 1 campaigns on record for this vehicle.

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 9 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…
02062842004-01-01Power TrainLEFT DRIVE SHAFT POPS OUT OF FINAL DRIVE AERIO MANUAL TRANSMISSION. *MJ
03063042004-01-01Electrical SystemALTERNATOR REPLACEMENT. *TT

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 2004 Aerio have open recalls?

NHTSA lists 1 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Aerio get?

EPA figures are 22 city / 28 highway / 24 combined mpg.