Workshop Manuals Factory service & repair Suzuki

Suzuki common faults and how to fix them

Faults that are well known on Suzuki models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Suzuki engine ticking noise: Vitara, Grand Vitara, XL-7, Esteem and Aerio (1999–2003)

Symptoms

A ticking noise from the top of the engine, heard with the engine cold or hot. It is most noticeable when the car has stood unused for a long time, and it can also appear after lifter or camshaft work.

Cause

Suzuki bulletin TS02 covers the 1999–2003 Vitara, Grand Vitara, Grand Vitara XL-7, Esteem and Aerio. When the engine stands, oil drains down out of the hydraulic valve lifters and air gets trapped in them, so they can't take up the valve clearance properly and tick.

Fix

Check the oil level and grade first. Before any major engine repair for the noise, the Suzuki ticking noise bulletin purges the air from the lifters by running the engine at about 2,000 rpm for around 20 minutes. If the tick goes away, nothing more is needed. If it stays, inspect the lifters and camshaft for wear as the manual describes. After any lifter or camshaft repair, run the same purge procedure before judging the result.

Repair instructions on this site

Sources: Suzuki technical service bulletin TS02 (December 2002).

Suzuki rear main seal leak: repeat leaks after replacement (1996–2003)

Symptoms

Oil drips from between the engine and gearbox, and the leak comes back soon after the rear main seal has been replaced.

Cause

Suzuki bulletin TS03 covers the 1996–1998 Sidekick Sport 1.8 and the 1999–2003 Vitara, Grand Vitara and XL-7, and 2002–2003 Aerio engines. It found that repeat rear main seal replacements were caused by not using the proper tools to fit the seal.

Fix

Confirm the leak is from the rear main seal and not the oil pan or the back of the cylinder head before removing the gearbox. Fit the new seal with the oil seal guide and installer named in the service manual, as the Suzuki rear main seal bulletin requires, and lubricate the lip lightly. Check the crankshaft surface for wear at the same time.

Repair instructions on this site

Sources: Suzuki technical service bulletin TS03 (May 2003).

Suzuki Aerio gear shift problem: shift cable clip recall 07V307000

Symptoms

The gear lever goes loose or no longer selects gears, often after a forceful shift into first. In the worst case the car can't be put into gear at all.

Cause

NHTSA recall 07V307000 covers certain cars with the five-speed manual gearbox. The clip that keeps the gear shift cable on the gear lever had the wrong shape, so it can touch the lever housing if the lever is pushed hard sideways into first. Repeated shifts like this can break the clip, and the cable then comes off the lever, so gears can no longer be changed.

Fix

Check with a Suzuki dealer that the recall has been done; the remedy is a new clip of the correct shape. If the lever has gone loose, check the clip at the base of the lever before suspecting the gearbox or the cables. The Suzuki Aerio recall notice describes the condition and remedy.

Repair instructions on this site

Sources: NHTSA recall 07V307000.

Suzuki Equator recall: front lower control arm bushing collars (2010)

Symptoms

Usually none until the part fails. If a bushing collar weld separates, the wheel alignment changes and the truck may pull, wander or feel unstable, with uneven tyre wear.

Cause

NHTSA recall 10V213000 covers certain 2010 Suzuki Equator pickups built between 20 November 2009 and 3 March 2010. The collars in the front suspension lower link bushings may have welds that do not meet strength specifications. A separated weld changes the alignment and can make the truck harder to control.

Fix

Check with a Suzuki dealer whether the recall has been done; dealers inspect the lower control arms and replace them where needed. If the truck pulls or wanders, have the front suspension and alignment checked straight away. The Suzuki Equator recall notice gives the build dates.

Repair instructions on this site

Sources: NHTSA recall 10V213000.