Problems owners report
Complaints filed with NHTSA about the 2004 Suzuki Aerio, by the system named in each complaint. One complaint can name several.
- Tires6
- Suspension3
- Power train2
- Electronic stability control (esc)1
- Vehicle speed control1
- Unknown or other1
- Exterior lighting1
- Visibility1
- Electrical system1
- Service brakes, hydraulic1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 1 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
New York safety inspections
At its first New York inspection the 2004 Suzuki Aerio failed the safety check 1.82% of the time — 18% less often than the average 2004 passenger car (2.21%). Median odometer at inspection: 125,348 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In New Zealand
221 2004 cars are on the New Zealand register; 99% arrived as used imports, 0% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 6 variants: combined 9.6–10.3 L/100 km (about 23–25 mpg US), CO₂ 221–237 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Aerio · Compact · Regular gasoline | 10.6 | 8.3 | 9.6 |
| Aerio · Compact · Regular gasoline | 10.8 | 8.3 | 9.7 |
| Aerio Fastback · Station wagon: Small · Regular gasoline | 10.8 | 8.3 | 9.7 |
| Aerio Fastback · Station wagon: Small · Regular gasoline | 10.9 | 8.5 | 9.8 |
| Aerio AWD · Compact · Regular gasoline | 11.3 | 9.0 | 10.3 |
| Aerio Fastback AWD · Station wagon: Small · Regular gasoline | 11.3 | 9.0 | 10.3 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
1 Transport Canada recall for the 2004 Suzuki Aerio.
| 2007233 12 Jul 2007 | Powertrain On certain vehicles, the retaining clip that secures the gear shift cable to the shift lever can contact the lever housing if excessive lateral force is applied… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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 HOUSING IF EXCESSIVE LATERAL FORCE IS APPLIED WHEN SHIFTING TO FIRST GEAR.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Suzuki told its dealers about the 2004 Suzuki Aerio: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10216558 | Reminder of the importance to conduct safety inspections for rust damage to suspension and related parts that could be caused by road salt or other chemicals applied to the roadway. |
| 10152052 | This Service Bulletin was sent by Suzuki Motor Corporation to its authorized Suzuki automobile distributors in the U.S., explaining the importance of proper inspection and maintenance of suspension lower arm ball joints to prevent the ball stud from becoming separated from the suspension lower arm. |
| 10028704 | SUZUKI: PARTS LIST FOR REPAIRING MANUAL TRANSAXLE 5TH GEAR CONCERNS SUCH AS POPPING OUT OF GEAR WHILE DRIVING. WORN OR FAILED 5TH GEAR SYNCHRONIZER, 5TH GEAR, AND RELATED PARTS. *PE |
| 10018529 | ABNORMAL REAR TIRE WEAR. *TT |
| 10015941 | DRIVER AND/OR PASSENGER SIDE MIRROR LOOSE. SUZUKI AERIO (RH420/RH423) *SC |
| 10015909 | MODIFICATION OF MAIN BEARING OIL CLEARANCE AND THE BEARING SELECTION PROCEDURE. 2002-2005 SUZUKI AERO-RH420/RH423 *SC |
| 10014812 | SERVICE MANUAL CORRECTION OF ALIGNMENT SPECIFICATIONS. *EH |
| 10008459 | ALTERNATOR REPLACEMENT. *TT |
| 10008453 | LEFT DRIVE SHAFT POPS OUT OF FINAL DRIVE AERIO MANUAL TRANSMISSION. *MJ |
NHTSA manufacturer communications (public domain)