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Discussion Starter #1
There is no MIL, no indication of anything wrong, and everything is working until it will not start. The intermittent behavior does not trip a DTC so I can't read a code to complain about. The engine cranks briskly but will not start. Testing shows the plugs are firing and when I've checked for fuel it was pumping, but then after testing, the engine started. I'm thinking its in the fuel pump system as I replaced the fuel pump at 97,000 miles which was this spring. the ground wire to the fuel tank was badly corroded when I cut if of so I removed about a foot of it and soldered a new section on which was fitted to the tank with a stainless steel fastener and copper anti-seize for added conductivity and prevent corrosion. After that repair it was working fine for the last five months until this intermittent problem has raised its ugly head. After failing to start four times in about three weeks it has now continued to work without incident for the last two weeks. Anybody got any ideas on where to look?
 

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Hello,

I'm not replying necessarily to your problem, BUT I am having the same problem, my 2002 Suzuki Aerio SX, was running last night (Tuesday evening, August 31, 2010.) I drove it home from college (full time student).

I parked it for the night. Got into it this morning (Wednesday, September 1, 2010), it cranks but refused to start.

I had classes today, so took public transportation.

Just quickly asked brother-in-law to use his diagnostic's checker tool, hooked up to my car.

Showed NO CODES AT ALL. Nothing in stored codes or anything.

Dark (nighttime here now, NY), so can't do much in the dark, too late for trouble light work. (No garage).

Tomorrow, Thursday, Sep't. 2nd, I'm starting with (as best I can) with the preliminary checks, spark, fuel, air flow (for combustion.)

However, I am only trained from self mechanics repairs and routine maintenance, on older model vehicles. Ones that had conventional spark plug wires to check for spark, fuel line, will trace, and turn key for electric fuel pump working.?

I have NO repair manual, (book), just got the car used from a friend.

I'm not sure about the spark plug / coil packs (think that they are called)? How to check for spark..?

Any help and idea are appreciated...

As I said, NO codes, haven't found any blown fuses yet, etc...

Thanks!

Have a nice day, evening...

God Bless,
Ed
 

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Discussion Starter #3
My car works great again. Cleaned up the ground connections and the fuel pump is humming like it should and everything else works great.
 

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Discussion Starter #4
The aerio is easy to test and the coils are a quick check as well, for those wondering these cars do "NOT" have timing belts and don't let anybody tell you other wise. They are driving a "PAIR" of chains which reduces the weight of the drive mechanism and unless one completely broke which would shut down the engine you have no slippage here like belt systems in other units. And the belts on the outside are auxiliary drive belts not timing.
 

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My car works great again. Cleaned up the ground connections and the fuel pump is humming like it should and everything else works great.
Just the type of information I'm looking for.... :)

I sent you a PM, and an e-mail.....

(I NEED MY CAR RUNNING and DRIVEABLE - ASAP......)

Thanks!

God Bless,
Ed
 

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The aerio is easy to test and the coils are a quick check as well, for those wondering these cars do "NOT" have timing belts and don't let anybody tell you other wise. They are driving a "PAIR" of chains which reduces the weight of the drive mechanism and unless one completely broke which would shut down the engine you have no slippage here like belt systems in other units. And the belts on the outside are auxiliary drive belts not timing.
not totally true.. this is a world wide forum..
in some countries, the aerio runs a 1.6L engine which uses a timing belt.
 

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Discussion Starter #7
I thank that man for a clarification before I helped somebody goof up their car. It can matter what country you got your car in. I have the Suzuki service manual for the 02 Aerio that is sold in the United States. Outside of that the engine ID would be the first place to check for individual component assignments.
 

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My car works great again. Cleaned up the ground connections and the fuel pump is humming like it should and everything else works great.
Also, the ground connection(s) I would be looking for are visible from underneath, rear of car?

If I crawled under the car, looking in the general direction of the rear seat floorboard area, where can I expect to locate this main (black) ground wire.?

So, does this snap over a thread, like a connector grommet.?

Is it held in place on the gas/fuel tank (sending unit/fuel pump) cover plate. (For lack of a better description.)?;)

Thanks!

God Bless,
Ed
 

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Check ground on throttle body to chassis

My Aerio had a bad ground connection from the throttle body to chassis. The ground had a plastic connection that went bad, so I removed the ground and replaced it with a heavier gauge wire to connect the 2 points.
Don't know if this helps good luck.
 

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My Aerio had a bad ground connection from the throttle body to chassis. The ground had a plastic connection that went bad, so I removed the ground and replaced it with a heavier gauge wire to connect the 2 points.
Don't know if this helps good luck.
I am surely open to all possible solutions, I need to have my car running again, and asap...

I have no other vehicle, and when you pay insurance and etc. on a car, one certainly wants to be able to use it and drive it.. :D

Hope whatever I need to do (try out) / check for and such will fix it... :)

Thanks again for all input...

God Bless,
Ed
 

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Discussion Starter #11
that small wire is bolted to the flange on the outside of the tank and runs up to the wiring harness. it will be black as it is painted on the tank.
 

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I thank that man for a clarification before I helped somebody goof up their car. It can matter what country you got your car in. I have the Suzuki service manual for the 02 Aerio that is sold in the United States. Outside of that the engine ID would be the first place to check for individual component assignments.
only the j-series engines had the timing chain. This is j18, j20-j20a, j23, and j24. found in some esteems/balenos, most aerios, some lianas, some SX4s, and the base Kizashi.
 

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Cleaned battery terminals - cranked - fired (popped) - Not again?

Hi Strontium90,

Well, to start my day at working on my car, it's so hot and HUMID - I can hardly stand it to do anything..!

When I was much younger and before my heart attack at age 44 (2000 - Labor Day), I was much thinner, and the heat NEVER bothered me as much..
:)

Well, there that I've said that, (haha) back to the car problems.... :lol:

Ok, first things first...

The battery terminals (especially the negative post were very dirty), green/fluffy build-up, mostly on the negative (ground circuit.)

I cleaned those, reattached.

Cranked the engine, it FIRED, ! *YEAH* - but only for about 1 sec, or less, in other words it popped (fired once on the cranking).

It has NOT tried to 'fire' / start again.

So, next I am going to try two things if possible, to try to gain access to underneath the car, near this ground wire that might be the culprit on the gas/fuel tank, correct..?

Also, if I can determine which line (rubber hosing) is the fuel supply line, to disconnect and see if there's fuel being delivered...to the injectors / cylinders, etc.)

Any tips...?

(Plus I'm going to walk see if my brother has a 'spare' battery perhaps to try, maybe the battery in my car is just TOO WEAK?)

I'm hearing mixed stories that the battery if too low in amperage, won't let the car start..?

What do you think...?

Thanks!

Have a nice day,

God Bless,
Ed
 

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Update - Car Is Running Again !

Update - Car Is Running Again ! :D

My brother and brother-in-law with further online searching and troubleshooting have my car running again...!

They were reading online, where the information suggested that they check the fuel pump relay.

Now, mind you, I have NOT been able to find a repair/service manual for the car, so I could not tell what relay did what?

They were working on the car, while I was in my home searching for still other possible solutions, and then they started it and it was running...! :D

What they did, was, remove ALL the relays, and reseated them one by one.

The relay terminals they said looked very clean, no signs of any corrosion or residue, but not sure if possibly a problem inside the relay/fuse box/panel, with the main wiring..?

Later we shall address looking into this more.

So, thanks for the help from all involved...

I'm happier now, and will be able to drive my Suzuki Aerio again..! :sunce:

Thanks!

Have a nice day/evening...

God Bless,
Ed
 
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