Top 10 2003 Suzuki Aerio Questions & Answers

I had the same problem and located the addendum to the owners manual. It's kind of overcomplicated it seems. Here is what it says:
1) Confirm all doors are closed and the key is out of the ignition.
2) Open the driver's door and put the key in the ignition within 10 seconds.
3) Remove the key within 10 seconds.
4) Push and release the driver's door switch 3 times within 20 seconds.
5) Insert the ingition key within 10 seconds.
6) remove the ignition key within 10 seconds
7) press and hold both "lock" and "unlock" on the transmitter for more than 5 seconds within 20 seconds of removing the key All doors will lock/unlock to confirm the process has been properly done.
8) Press "lock" or "unlock" on the transmitter within 5 seconds of completing step 7. All the doors will lock/unlock to confirm that the process was properly done.
At this point the transmitter has been properly programmed.

Of course, this didn't help me. My transmitter still does not work. I did confirm the procedure with a known good transmitter, so it is valid. If the lock/unlock does not happen in step 7, you more than likely have a bad transmitter.

TIMING BELT SHOULD BE 60,000 MILE CHANGE

You should be useing 5w30 oil in this car.

Crankshaft Position (CKP) Sensor - Removal and Installation

Removal
Remove engine with transmission from vehicle referring to ENGINE ASSEMBLY REMOVAL AND INSTALLATION .
Remove transmission from engine and then remove flywheel or drive plate from crankshaft.
Disconnect connector from crankshaft position sensor.
Remove crankshaft position sensor (1) from cylinder block (2).

Installation
Reverse removal procedure noting the following.
Check to make sure that crankshaft position sensor (1) is free from any metal particles and damage.
Apply engine oil to O-ring of sensor.
Install crankshaft position sensor to cylinder block (2) with specified torque.
Tightening torque
Crankshaft position sensor bolt (a): 6 N.m (0.6 kg-m, 4.5 Lb-ft)


Fig. 28: Installing Crankshaft Position Sensor To Cylinder Block

Connect connector and fix wire harness with clamp securely.

Courtesy of SUZUKI OF AMERICA CORP.

Hope helps!!!

A code P0420 may mean that one or more of the following has happened:

•Leaded fuel was used where unleaded was called for
•An oxygen sensor is not reading (functioning) properly
•The engine coolant temperature sensor is not working properly
•Damaged or leaking exhaust manifold / catalytic converter / exhaust pipe
•Retarded spark timing
•The oxygen sensors in front and behind the converter are reporting too similar of readings

Some suggested steps for troubleshooting a P0420 error code include:

•Check for exhaust leaks at the manifold, pipes, catalytic converter. Repair as required.
•Use a scope to diagnose the oxygen sensor operation (Tip: The oxygen sensor in front of the catalytic converter normally has a fluctuating waveform. The waveform of the sensor behind the converter should be more steady).
•Inspect the downstream heated oxygen sensor (HO2), replace if necessary
•Replace the catalytic converter
One thing to note is that many vehicle manufacturers offer a longer warranty on emissions-related parts. So if you have a newer car but it's out of it's bumper-to-bumper warranty, there still may be warranty on this type of problem. Many manufacturers give a five year, unlimited mileage warranty on these items. It's worth checking into.

By removing automatic transmission oil pan out from gearbox.

1. Filter for 4-Speed, transmissionmfrcode : 60-40LE.
AC Delco Automatic Transmission Filter
2003 Suzuki Aerio: GS all engines, S all engines, SX all engines. AC DELCO TRANSMISSION OIL FILTER -- Magnetic 3/8 in. in-line filter; A high quality, direct fit OE replacement transmission oil filter; With 12-month or 12,000-mile AC Delco warranty. Price around $40. 2. Filter for 4-Speed, transmissionmfrcode : MX1. AC Delco Automatic Transmission Filter
2003 Suzuki Aerio: GS all engines, S all engines, SX all engines. AC DELCO TRANSMISSION OIL FILTER -- 15 holes; A high quality, direct fit OE replacement transmission oil filter; With 12-month or 12,000-mile AC Delco warranty.


3. Filter for 2003 Suzuki Aerio: GS, S, SX all 2,0 liters 4 cyl. engines.
Beck Arnley Automatic Transmission Filter
2003 Suzuki Aerio
BECK ARNLEY AUTOMATIC TRANSMISSION FILTER -- A high quality, direct-fit OE replacement automatic transmission filter.

Hi! Please don't forget to rate! Thanks!

Cylinder head bolt torque sequence-2.0L and 2.3L engines

Apply engine oil to the bolt threads and tighten the cylinder head bolts, in sequence, using the following 6 Steps:

• Step 1: 38.5 ft. lbs. (53 Nm)
  
• Step 2: 61 ft. lbs. (84 Nm)
  
• Step 3: Loosen all of the cylinder head bolts
  
• Step 4: 38.5 ft. lbs. (53 Nm)
  
• Step 5: 76 ft. lbs. (105 Nm)
  
• Step 6: Bolt M6 (bottom left of cylinder head) - 8 ft. lbs. (11 Nm)
  

You are most likely not getting any cold air because your A/C compressor is not engaging when you hit the switch. A number of different problems could give you this result.

First, you could have a blown fuse; that would be the cheapest and easiest solution. Second, your A/C system may be low on freon, and a low-pressure safety valve may be keeping the system from operating. However, rather than simply adding some freon to your system, it makes more sense to borrow a set of A/C pressure gauges and hook one up to the low side of your system (i.e., at the port where you would otherwise add R-134a refrigerant) to get an accurate pressure reading. A slightly low reading indicates that natural wear and tear on the system has let enough of the R-134a out of your system that it needs to be replaced. However, an inappropriately high or low reading not only indicates that you're low on freon, but also that there's a more substantial leak somewhere in your system. In this situation, adding refrigerant without addressing the leak may damage your compressor over time, as crucial lubricating oil drips out of the system and isn't replaced. A third and less likely cause for your problem is that the dashboard switch to turn on your A/C may be broken. This does happen, though if the switch is lighting up when you engage it, it's probably not the problem. Fourth, and most expensive, your A/C compressor may have failed. This would be somewhat unusual in a 2005 car, although it's not out of the question if you have used your A/C system a great deal.

Because of the cost of replacing damaged A/C components, it may make the most sense to let a certified shop handle any A/C system repairs once you have an idea of what's wrong. Full servicing of your system will evacuate all existing oil and refrigerant, identify and fix any leaks, and then vacuum test the system before filling it with fresh oil and R-134a. The end result will very likely work better and last longer than the cheap fix of dumping a can of R-134a into the system and hoping for the best.

A number of years ago, I lost all freon and pressure in my A/C system when a rock kicked up from the street hit the A/C cooling condenser and caused a pinhole leak. I couldn't find the leak; I only knew that my A/C system had lost pressure. That's the kind of problem that an A/C service center will be able to diagnose and fix much better than someone without the right equipment.

Component location diagrams for most 2003 Suzuki Aerio cars and light trucks sold in the U.S. from 1990+.
Ignition System Components Location Diagram for 2003 Suzuki Aerio 2.0 L4 GAS
Components on diagram:

TP Sensor

Ignition Coil

ECM

MAF Sensor

CMP Sensor

Electronic Shift Control System Components Location Diagram for 2003 Suzuki Aerio 2.0 L4 GAS
Components on diagram:

Data Link Connector

Transmission Range Sensor

Throttle Position Sensor

Pressure Control Solenoid Valve

Battery

Instrument Panel For Connector Layout Diagram Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

Clutch Switch

Thermistor

Brake Light Switch

Blower Motor Relay

Heater Fan Motor

Instrument Panel Harness Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

Wiper Switch

Washer Switch

Data Link Connector

Turn Signal Relay

Radio

Headlight System Location Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

Headlight Relay

Headlight

Clearance Light

Headlight Diode

Clearance Light Relay

Fuel System Components Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

Fuel Pump Relay

Fuel Tank Pressure Sensor

EVAP Canister

Fuel Tank Pressure Control Valve

Fuel Filler Cap

Floor For Single Unit Parts Diagram for 2003 Suzuki Aerio 2.0 L4 GAS
Components on diagram:

Wheel Speed Sensor

ABS Control Module

G Sensor

Air Bag Control Module

EVAP Canister Vent Valve

Instrument Panel For Ground Point Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

Instrument Panel Ground Points

Engine Compartment For Single Unit Parts Diagram for 2003 Suzuki Aerio 2.0 L4 GAS
Components on diagram:

Throttle Position Sensor

Horn Relay

Radiator Fan Control Relay

Cruise Control Module

Condenser Fan Relay

Engine Compartment Components Diagram for 2003 Suzuki Aerio SX 2.0 L4 GAS
Components on diagram:

MAP Sensor

Knock Sensor

Noise Suppressor

Heated Oxygen Sensor

which fan? there can be 3 fans.
1 cab blower
engine fan
a/c condenser fan/
why not say , my x is dead, name x then ask for fuse and relay
answers are all USA spec, car, this is USA forum.
ill toss dice and land , engine cooling fan. (no engine stated so...."?)

engine rad fan, fuse 23 (if blown kills spark so.... not that...)
Radiator fan control relay #1 and 2 and 3
there are 3 relays, both fed from fuse 8
a 3 speed fan it is. , fan has 4 wires , one ground and 3 speed feeds.

i have the schematic.
below is under hood fuse box. main.
if you were to look at lid its marked.