NHTSA lists 2 safety recalls and 19 owner complaints for the 2002 Suzuki Aerio. Most complaints involve service brakes, hydraulic (4) and suspension (4). The EPA rates it 25–26 mpg combined.
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.
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) VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 212, 'WINDSHIELD MOUNTING." THE WINDSHIELD MAY NOT BE PROPERLY SECURED TO THE VEHICLE BODY DUE TO INSUFFICIENT ADHESION BETWEEN THE PAINT APPLIED DURING THE SECOND-STAGE PAINTING PROCESS AND THE PAINT APPLIED DURING FINAL-STAGE PAINTING.
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
“AFTER SEVERAL MISDIAGNOSES FOR THE SAME PROBLEM WITH MY CAR GOING INTO GEARS THE PROBLEM WAS RESOLVED TWO MONTHS AFTER THE CAR WENT OUT OF WARRANTY. I WAS CHARGED TO FIX THE PROBLEM WHICH WAS COMPLETELY UNFAIR. THE FIRST TIME I BROUGHT THE CAR IN THE SERVICE MANAGER SAID I WASN''T PUSHING HARD ENOUGH ON THE BRAKE. THE SECOND TIME HE SAID IT WAS DO TO THE COLD WEATHER. THE THIRD TIME HE SAID THAT UNTIL THE CAR COULD NEVER GET BACK INTO GEAR HE WAS UNABLE TO FIX IT UNDER WARRANTY. THE FOURTH TIME HE FIXED A PART AND IT STILL HAD THE SAME PROBLEM. THE FIFTH TIME I TOOK IT TO ANOTHER SUZUKI DEALERSHIP WHERE THEY PROCEEDED TO TELL ME THAT THE OTHER DEALERSHIP DID NOT INSTALL THE PART CORRECTLY. THEN THE SIXTH TIME THEY SAID IT IS A DIFFERENT PART AND FIXED IT AND CHARGED ME BECAUSE IT IS OUT OF WARRANTY. THIS PROBLEM TOOK ONE YEAR AND ONE MONTH TO FIX. THE DISTRICT MANAGER SAID BECAUSE IT IS OUT OF WARRANTY THAT HE WOULD NOT APPROVE THE COST OF FIXING IT. EVEN THOUGHT THE PROBLEM STARTED AFTER ONLY TWO YEARS OF ME OWNING THE CAR AND WAS CLEARLY BACK WHEN IT WAS UNDER WARRANTY. THE CAR TO THIS DATE STILL DOESN''T HAVE 30,000 MILES ON IT.”
“WHILE TURNING RIGHT AT 45 MPH THE LOWER CONTROL ARM SNAPPED. CONSUMER LOST STEERING CONTROL AND HIT A POLE. VEHICLE WAS TOWED. DEALERSHIP REPAIRED THE LOWER CONTROL ARM. *AK THE CONSUMER STATED THE AIR BAGS DID NOT DEPLOY AS DESIGNED. UPDATED 02/09/06. *JB”
“QUITE A FEW OF THE SCREWS OR GROMMETS THAT HOLD THE BODY PARTS ONTO MY CAR HAVE FELL OUT. MY FRONT BUMPER WAS BARELY BUMPED AND IT BROKE ONE OF THE CLIPS ON THE BUMPER AND IS NOW TIED UP WITH A SHOE STRING. MY A/C COMPRESSOR HAS ALREADY HAD TO BE REPLACED AND FOR SOME REASON THE COOLING FANS ARE NOT WORKING PROPERLY. THE STRUCTURE ON THIS CAR IS POOR. THE LOCK TO THE DRIVERS SIDE DOOW JUST SPINS NOW, SO IT NEEDS TO BE REPLACE. I HAVE ALREADY HAD TO REPLACE THE TRUNKS LOCK DUE TO SAME PROBLEM. I HAVE HAD TO REPLACE THE IGNITION SWITCH ALSO DUE TO KEY NOT OPERATING PROPERLY. CLIPS FROM BOTH BUMPERS HAVE FALLEN OFF FOR NO REASON. I EXPECTED MORE FROM A SUZUKI CAR. I BELILEVE THIS WILL BE MY LAST PURCHASE FROM THEM. *TR”
Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.
| Version | City | Hwy | Comb. | Fuel / yr | CO₂ g/mi |
|---|---|---|---|---|---|
| Aerio Man 5-spd, 4 cyl, 2.0 L · Front-Wheel Drive | 23 | 30 | 26 | $2,400 | 342 |
| Aerio Auto 4-spd, 4 cyl, 2.0 L · Front-Wheel Drive | 23 | 28 | 25 | $2,500 | 355 |
| Aerio SX Auto 4-spd, 4 cyl, 2.0 L · Front-Wheel Drive | 22 | 28 | 25 | $2,500 | 355 |
| Aerio SX Man 5-spd, 4 cyl, 2.0 L · Front-Wheel Drive | 23 | 29 | 25 | $2,500 | 355 |
| Item | Miles | Time | Note |
|---|---|---|---|
| Engine oil & filter | 5,000–10,000 mi | 6–12 months | Follow the oil-life monitor if fitted |
| Tire rotation | 5,000–7,500 mi | Every oil change | Check pressure monthly |
| Engine air filter | 15,000–30,000 mi | 1–2 years | Sooner in dusty areas |
| Cabin air filter | 15,000–25,000 mi | 1–2 years | |
| Brake fluid | — | 2–3 years | Absorbs moisture over time |
| Coolant | 60,000–100,000 mi | 5–10 years | Long-life coolants last longer |
| Spark plugs | 60,000–100,000 mi | — | Iridium/platinum plugs at the long end |
| 12V battery | — | 3–5 years | Heat shortens battery life |
2 safety recalls as of Nov 10, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.
Owners filed 19 complaints with NHTSA. The most-cited components are service brakes, hydraulic (4), suspension (4), engine and engine cooling (3). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.
The EPA rates the 2002 Suzuki Aerio at 25–26 mpg combined, depending on engine and drivetrain (4 versions rated).