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Suzuki1998–2015 Critical issues documented

Suzuki Every: common faults & what to check

Thinking about buying a used Suzuki Every (1998–2015) in New Zealand? We've documented 14 known faults for this model spanning engine, suspension, body & rust, and transmission. Each researched and verified before it's published. The most serious issues here are rated critical. Every one is listed below with its symptoms and repair cost, and each has its own page with where to look and what to ask the seller. Free, no account needed.

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  • Reported stolen
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  • NZ owned and operated

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14

Documented faults

Critical

Most serious

$400–$1,600

Typical repair

7

Systems covered

Which Suzuki Every are you looking at?

1 generation variant documented. Pick the shape you recognise: the faults, the servicing and the timeline below all narrow to it. Free, no account needed.

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

Which engine is in it? These cover every year of this model.

0.66 petrol (kei)· 0.66 litre petrol

Start your free check on this Suzuki Every

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Suzuki Every

Free. The paid plate check is separate, and stays optional.

Can't confirm for this car

Suzuki Every

Nothing has been narrowed yet, so nothing below is a claim about a particular car. Pick a year and an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

matched on no vehicle context

What to look out for

The checks worth doing on a Suzuki Every before you hand over any money. Every documented fault is listed below, each with its own page.

  • Serious issue

    Check for blue or grey smoke on a sustained deceleration run.

    See why

    K6A Turbo Oil Feed Line Clogging Leading to Turbo Bearing Failure

    The K6A 0.66T turbocharger is fed via a small-diameter oil supply banjo bolt and feed line that is highly sensitive to oil sludge from extended service intervals. Partial or full blockage starves the floating turbo bearing of lubrication, causing rapid heat build-up and bearing failure. The small displacement engine is often worked hard in commercial delivery use, compounding the risk when oil changes are deferred beyond 5,000 km.

    What you would notice

    • Persistent blue or grey smoke from the exhaust on overrun and deceleration
    • High-pitched whining or grinding noise from the turbo area that worsens under boost
    • Noticeable loss of power and boost pressure above 3,000 rpm
    • Oil consumption with no visible external leak

    Typically $850–$2,000 to put right.

  • Serious issue

    Check that the spring leaves are correctly interleaved and that the centre U-bolt is tight.

    See why

    Rear Leaf Spring Main Leaf Fatigue Cracking Under Commercial Load

    The Every van's rear suspension uses a multi-leaf spring pack designed for a modest payload. Commercial operators frequently exceed the rated load, particularly with the DA52V and DA62V used as courier or trade vans. Repeated overloading causes fatigue cracks to initiate in the main leaf near the spring eye or centre bolt. A cracked main leaf can separate suddenly, dropping the axle and causing loss of vehicle control.

    What you would notice

    • Clunking or banging from the rear suspension over bumps, particularly under load
    • Rear of the vehicle sitting noticeably lower on one side when loaded or at rest

    Typically $450–$1,100 to put right.

  • Costly issue

    Inspect the floor, sills, chassis rails and rear door frames for rust, probing soft spots for structural corrosion.

    See why

    Underfloor and sill rust on commercial vans

    The Every's floor, sills, chassis rails and rear door frames rust with age and commercial use carrying wet or corrosive loads, worsened by NZ coastal conditions. The cab-over layout exposes front footwells. Structural floor rust is a WoF failure.

    What you would notice

    • Rust through the floor
    • Corroded sills and rails
    • Rust around rear door frames
    • Soft footwells

    Typically $500–$3,000 to put right.

  • Costly issue

    Lift all floor mats and press firmly across the floor — any flex or softness indicates rust perforation.

    See why

    Floor Pan and Inner Chassis Rail Rust

    The DA62 Every's rear-engine layout and thin-gauge floor steel make the floor pan and inner chassis rails particularly vulnerable to corrosion in NZ's wet and coastal conditions. Rust typically begins at seam welds beneath floor mats and around the spare wheel well, progressing to structural perforation. Structural floor rust causes WOF failure in NZ and panel repair costs escalate significantly once the chassis rail is compromised.

    What you would notice

    • Soft or springy feeling underfoot in the cabin floor
    • Visible rust or perforations in the floor when inspected from inside
    • Rust staining or bubbling on the underside of the floor pan from below

    Typically $500–$4,000 to put right.

  • Costly issue

    Test drive the vehicle at 30-40 km/h with very light throttle on a flat road and feel for rhythmic shuddering through the seat and gearshift.

    See why

    CVT Belt Judder Under Light Throttle Load

    The DA17V CVT uses a steel push-belt running between variable-diameter pulleys with a sub-transmission providing high and low range. Degraded CVT fluid loses its friction-modifier additives, causing the belt to momentarily slip and re-grip against the pulley faces under partial-throttle load at low to moderate speeds. This produces a characteristic juddering or shuddering sensation felt through the drivetrain at 20-50 km/h under light acceleration. Early-stage judder is often fully resolved by a CVT fluid drain and refill with Suzuki-approved CVTF fluid. If fluid-neglected, progressive belt and pulley surface micro-scoring causes mechanical judder that fluid alone cannot cure, requiring valve body cleaning or CVT unit replacement.

    What you would notice

    • Rhythmic shudder or vibration at 20-50 km/h under light throttle
    • Judder that diminishes under harder acceleration or at higher speeds
    • Shudder more pronounced when CVT fluid is cold
    • Sensation sometimes described as driving over small rumble strips
    • Occasional CVT warning light in advanced cases

    Typically $280–$3,500 to put right.

  • Costly issue

    Drive under load feeling for shudder, slip and harsh shifts, and ask when the transmission fluid was last changed.

    See why

    Automatic/CVT wear under commercial load

    The Every's automatic and CVT transmissions wear under constant stop-start commercial loads, showing as shudder, slipping, whine or harsh shifts, especially where fluid was never serviced. Overloading worsens it. Rebuild or replacement is costly relative to the van's value.

    What you would notice

    • Shudder or slipping
    • Whine from transmission
    • Harsh or delayed shifts
    • Hesitation under load

    Typically $700–$2,800 to put right.

See all 14 documented issuesEverything researched for the Suzuki Every, including 2 rated critical.
Depends on which engine this Suzuki Every has — 14Each of these is documented for one particular engine. Pick the year and engine above to see which of them apply.
Engine, transmission & cooling7

01K6A Turbo Oil Feed Line Clogging Leading to Turbo Bearing Failure

Check for blue or grey smoke on a sustained deceleration run.petrol2001–2013EngineRead the full fault: symptoms, where to look, what to ask the seller

02CVT Belt Judder Under Light Throttle Load

Test drive the vehicle at 30-40 km/h with very light throttle on a flat road and feel for rhythmic shuddering through the seat and gearshift.petrol2015 onwardTransmissionRead the full fault: symptoms, where to look, what to ask the seller

03Automatic/CVT wear under commercial load

Drive under load feeling for shudder, slip and harsh shifts, and ask when the transmission fluid was last changed.petrol2000 onwardTransmission
CommonTransmission $700–$2,800 to fix

Can't confirm for this car

The Every's automatic and CVT transmissions wear under constant stop-start commercial loads, showing as shudder, slipping, whine or harsh shifts, especially where fluid was never serviced. Overloading worsens it. Rebuild or replacement is costly relative to the van's value.

Symptoms to notice

  • Shudder or slipping
  • Whine from transmission
  • Harsh or delayed shifts
  • Hesitation under load

What to check

Drive under load feeling for shudder, slip and harsh shifts, and ask when the transmission fluid was last changed.

Where to look: Automatic or CVT transmission

Ask the seller

  • “Any shudder or slipping from the transmission?”
  • “When was the fluid last serviced?”
  • “Has it been overloaded?”

04F6A/K6A turbo oil consumption and wear

Check oil level and colour, look for blue smoke and turbo whine, and ask about oil-top-up frequency given commercial use.petrol2000 onwardEngine
CommonEngine $400–$1,800 to fix

Can't confirm for this car

The Every van's F6A and K6A 0.66 engines, especially turbo versions, consume oil at higher commercial mileage through valve seals and rings, and the small sump makes levels drop fast, risking turbo damage. Hard delivery use accelerates it. Frequent oil checks are essential.

Symptoms to notice

  • Oil level dropping quickly
  • Blue smoke on start or overrun
  • Turbo whine on turbo models
  • Fouled spark plugs

What to check

Check oil level and colour, look for blue smoke and turbo whine, and ask about oil-top-up frequency given commercial use.

Where to look: Engine and turbocharger

Parts involved: Turbocharger.

Ask the seller

  • “How often does it use oil?”
  • “Any smoke or turbo whine?”
  • “What is the commercial mileage?”

05K6A Timing Chain Tensioner Cold-Start Rattle

Cold-start the engine from fully cold and listen immediately for a metallic rattle from the top of the engine that resolves within 5–10 seconds.petrol2001–2013Engine
CommonEngine $250–$700 to fix

Can't confirm for this car

The K6A engine uses a hydraulic timing chain tensioner that drains back to the sump after extended periods of non-use. On cold start, the tensioner takes several seconds to build oil pressure and take up slack in the chain, producing a characteristic metallic rattling from the camshaft drive area. Repeated occurrences over high mileage accelerate chain and guide wear, ultimately risking chain jump and valve-to-piston contact if ignored.

The front of a dual overhead camshaft engine with the timing cover removed, exposing the timing chain and sprockets.Example of the part — not this vehicle

The front of a twin-cam engine with the timing cover off — chain, sprockets and guides.

Logansenf · CC BY-SA 4.0 · Wikimedia Commons

Symptoms to notice

  • Distinct metallic rattling noise from the engine on cold start that fades as oil pressure builds
  • Rattle persisting longer than 10 seconds, or recurring at idle when the engine is warm, indicating advanced tensioner or chain wear

What to check

Cold-start the engine from fully cold and listen immediately for a metallic rattle from the top of the engine that resolves within 5–10 seconds. If the rattle persists beyond 15 seconds or recurs at operating temperature, the tensioner or chain is worn. Check for any fault codes or prior tensioner replacement in the service history. Inspect oil level and condition — low or degraded oil worsens drain-back.

Where to look: Timing chain tensioner on the rear face of the K6A block, behind the engine access hatch under the load floor

Parts involved: Timing chain.

Ask the seller

  • “Does the engine make any rattling noise in the first few seconds after a cold start?”
  • “Has the timing chain or tensioner ever been replaced?”

06R06A Turbo Boost Control Solenoid Failure

With the engine running, check for codes P0045-P0047.petrol2015 onwardEngine
OccasionalEngine $280–$680 to fix

Can't confirm for this car

The turbocharged R06A-T engine uses an electronic boost control solenoid (turbo control valve) to regulate wastegate actuator pressure and modulate boost delivery. The solenoid is exposed to engine bay heat cycling and vibration; the internal coil and plunger degrade over time, causing an open-circuit or sticky-valve condition. Failure results in the ECU losing accurate boost control, triggering limp-home mode to protect the engine. Symptoms appear intermittently initially before becoming persistent. Fault codes P0045 (open circuit), P0046 (range/performance), or P0047 (low circuit) are set. Replacement of the solenoid alone typically restores normal function if the turbo and wastegate actuator are mechanically sound.

Symptoms to notice

  • Engine enters limp-home mode with reduced power
  • Fault codes P0045, P0046, or P0047 stored
  • Boost pressure erratic — either over-boost or significant under-boost
  • Intermittent loss of turbo power under load
  • Engine warning light illuminated

What to check

With the engine running, check for codes P0045-P0047. Inspect the boost control solenoid wiring harness connector for corrosion or cracking insulation. The solenoid can be tested for resistance (typically 20-40 ohms); out-of-specification reading confirms failure. Inspect vacuum lines to and from the solenoid for cracks. If a workshop inspection is possible: Connect an OBD-II scanner and read boost-related fault codes before clearing them.

Where to look: Boost control solenoid mounted on intake manifold or engine block near the turbocharger; connected to wastegate actuator via vacuum hose

Parts involved: Turbocharger.

Ask the seller

  • “Has the vehicle ever entered limp mode or shown reduced boost?”
  • “Are there any current or historic fault codes for the turbo boost control circuit?”
  • “Has the turbo boost control solenoid been replaced?”
  • “Does the vehicle pull strongly through the rev range without hesitation under load?”

074WD viscous coupling wear

On 4WD vans test for driveline binding on slow tight turns and check 4WD engagement and rear driveline noise.petrol2000 onwardTransmission
OccasionalTransmission $400–$1,500 to fix

Can't confirm for this car

On 4WD Every vans the viscous coupling and rear driveline wear with age, causing binding on tight turns, reduced 4WD engagement and driveline vibration. Neglected differential oil accelerates the wear. Coupling replacement requires specialist kei parts.

Symptoms to notice

  • Binding on tight turns
  • Weak or no 4WD drive
  • Driveline vibration
  • Whine from rear driveline

What to check

On 4WD vans test for driveline binding on slow tight turns and check 4WD engagement and rear driveline noise.

Where to look: Viscous coupling and rear driveline

Parts involved: Differential.

Ask the seller

  • “Does the 4WD work without binding?”
  • “Any driveline vibration or whine?”
  • “When was the diff oil changed?”
Electrical1

01Electric Power Steering Motor or Controller Failure (DA62V EPS Variants)

Switch on ignition and confirm the EPS warning light extinguishes within a few seconds.petrol2001–2013Electrical
OccasionalElectrical $500–$1,600 to fix

Can't confirm for this car

Later DA62V Every models equipped with column-mounted electric power steering (EPS) experience failure of either the EPS motor or the EPS electronic control unit (ECU). The failure typically presents as sudden loss of power assistance, making steering heavy, particularly at low speed and when parking. The EPS ECU is susceptible to moisture ingress and heat cycling, and the motor brushes wear over high mileage. This is an MOT/WOF fail item in most markets.

Symptoms to notice

  • EPS warning light illuminated on the instrument cluster, with or without accompanying loss of power assistance
  • Steering suddenly becomes heavy and requires noticeably greater effort, particularly at parking speeds

What to check

Switch on ignition and confirm the EPS warning light extinguishes within a few seconds. Drive at low speed and feel for uniform, light steering assistance throughout the turning arc. Any sudden heaviness, jerkiness, or the EPS light illuminating during a turn indicates motor or controller fault. Inspect the EPS ECU connector for corrosion or moisture damage. If a workshop inspection is possible: Scan for EPS fault codes with a compatible OBD or Suzuki-specific scan tool.

Where to look: EPS motor and torque sensor mounted on the steering column under the dashboard; EPS ECU typically located behind the instrument cluster or under the dash on the passenger side

Parts involved: Steering rack.

Ask the seller

  • “Has the EPS warning light ever appeared on the dashboard?”
  • “Does the steering feel consistently light and assisted, or has it ever suddenly gone heavy?”
Body, brakes, suspension & interior5

01Rear Leaf Spring Main Leaf Fatigue Cracking Under Commercial Load

Check that the spring leaves are correctly interleaved and that the centre U-bolt is tight.petrol1998–2013Suspension
OccasionalSuspension $450–$1,100 to fix

Can't confirm for this car

The Every van's rear suspension uses a multi-leaf spring pack designed for a modest payload. Commercial operators frequently exceed the rated load, particularly with the DA52V and DA62V used as courier or trade vans. Repeated overloading causes fatigue cracks to initiate in the main leaf near the spring eye or centre bolt. A cracked main leaf can separate suddenly, dropping the axle and causing loss of vehicle control.

Symptoms to notice

  • Clunking or banging from the rear suspension over bumps, particularly under load
  • Rear of the vehicle sitting noticeably lower on one side when loaded or at rest

What to check

  1. Check that the spring leaves are correctly interleaved and that the centre U-bolt is tight.
  2. Note if the vehicle sits lower on one side when loaded, indicating a broken or fatigued spring.
  3. Look for fresh rust streaks or paint separation along the spring length as an indicator of cracking.
  4. If a workshop inspection is possible: With the vehicle unloaded and on a hoist, inspect each leaf spring pack closely along the full length of every leaf for hairline cracks, particularly near the centre bolt and spring eye ends.

Where to look: Rear axle leaf spring packs, one each side, running longitudinally beneath the cargo floor between front and rear spring hangers

Parts involved: Rear leaf spring.

Ask the seller

  • “Has this vehicle been used commercially for courier or trade delivery work?”
  • “Have the rear leaf springs ever been inspected or replaced?”

02Floor Pan and Inner Chassis Rail Rust

Lift all floor mats and press firmly across the floor — any flex or softness indicates rust perforation.petrol2001–2015Body & Rust
CommonBody & Rust $500–$4,000 to fix

Can't confirm for this car

The DA62 Every's rear-engine layout and thin-gauge floor steel make the floor pan and inner chassis rails particularly vulnerable to corrosion in NZ's wet and coastal conditions. Rust typically begins at seam welds beneath floor mats and around the spare wheel well, progressing to structural perforation. Structural floor rust causes WOF failure in NZ and panel repair costs escalate significantly once the chassis rail is compromised.

Symptoms to notice

  • Soft or springy feeling underfoot in the cabin floor
  • Visible rust or perforations in the floor when inspected from inside
  • Rust staining or bubbling on the underside of the floor pan from below

What to check

  1. Lift all floor mats and press firmly across the floor — any flex or softness indicates rust perforation.
  2. Inspect from under the vehicle with a torch along both chassis rails and all floor seam welds.
  3. Check the spare wheel well for standing water or rust.

Where to look: Floor pan underside, inner chassis rails both sides, spare wheel well

Parts involved: Chassis and structural rust.

Ask the seller

  • “Has the underside been treated or inspected, and were any rust repairs noted?”
  • “Does it hold a current WOF, and was any rust noted on the inspection?”

03Underfloor and sill rust on commercial vans

Inspect the floor, sills, chassis rails and rear door frames for rust, probing soft spots for structural corrosion.petrol2000 onwardBody & Rust
Very commonBody & Rust $500–$3,000 to fix

Can't confirm for this car

The Every's floor, sills, chassis rails and rear door frames rust with age and commercial use carrying wet or corrosive loads, worsened by NZ coastal conditions. The cab-over layout exposes front footwells. Structural floor rust is a WoF failure.

Symptoms to notice

  • Rust through the floor
  • Corroded sills and rails
  • Rust around rear door frames
  • Soft footwells

What to check

Inspect the floor, sills, chassis rails and rear door frames for rust, probing soft spots for structural corrosion.

Where to look: Floor, sills, chassis rails, rear doors

Parts involved: Body corrosion.

Ask the seller

  • “Any floor or chassis rust?”
  • “Does it pass a current WoF?”
  • “Has rust repair been done?”

04Front Brake Caliper Slide Pin Seizure Causing Uneven Pad Wear

petrol1998–2013Brakes
CommonBrakes $150–$500 to fix

Can't confirm for this car

The front sliding-type disc brake calipers on both the DA52V and DA62V are prone to slide pin seizure from corrosion, particularly on vehicles used commercially or in high-humidity environments. Seized pins prevent the caliper from releasing fully after braking, causing the inner or outer brake pad to drag continuously against the disc. This causes premature and uneven pad wear, disc scoring, brake pull, and in severe cases brake fade from residual heat.

Symptoms to notice

  • Vehicle pulling noticeably to one side under braking, with the pull consistent rather than intermittent
  • One front brake pad worn significantly thinner than the other within the same caliper, or compared with the opposite side

What to check

After a normal drive, carefully feel each front wheel hub near the disc (avoiding contact with the disc itself) for excessive heat compared to the other side — a seized pin causes one side to run hot. Inspect pads for uneven thickness side-to-side within the same caliper, and inspect the disc for scoring or hot spots. Check rubber slide pin boots for splitting or dislodgement. If a workshop inspection is possible: Remove the caliper and extract each slide pin; they should pull out freely by hand and slide back in smoothly after cleaning.

Where to look: Front brake calipers mounted on the front axle knuckle carriers, one each side; slide pins run through the caliper bracket parallel to the axle

Parts involved: Brake disc and pads.

Ask the seller

  • “When were the front brake pads last replaced, and were both sides replaced at the same time?”
  • “Does the vehicle pull to one side when braking?”

05Front Torsion Bar Stabiliser End Link Wear and Failure

Have an assistant move the steering while you feel for knock at the end link joint.petrol1998–2013Suspension
Very commonSuspension $90–$280 to fix

Can't confirm for this car

The Every's front suspension uses a torsion bar arrangement with stabiliser end links connecting the bar to the lower suspension arms. The rubber-bushed or ball-jointed end links wear and develop play over typical mileages above 100,000 km, producing a clunking noise over uneven road surfaces and contributing to increased body roll and degraded front suspension geometry.

Symptoms to notice

  • Clunking or knocking noise from the front suspension when driving over rough or uneven road surfaces
  • Increased body roll in corners compared to when the vehicle was new

What to check

Have an assistant move the steering while you feel for knock at the end link joint. Inspect the rubber bushes or ball-joint boot for cracking, splitting, or grease leakage. Drive over a series of small bumps and listen for a clunk from the front that is absent when a load is placed on the bumper. If a workshop inspection is possible: With the vehicle on a hoist and the front wheels hanging free, grasp each end link and check for vertical or lateral play.

Where to look: Front stabiliser end links connecting the torsion bar/stabiliser bar to the lower control arm on each side, behind the front wheels

Ask the seller

  • “Have the front stabiliser end links been replaced at any stage?”
  • “Does the front suspension clunk over speed bumps or rough roads?”
Fluid leaks1

014WD Rear Coupling Seal Leak

Inspect the rear coupling from underneath for oil weeping or staining on the surrounding area.petrol2001–2015Fluid Leaks
OccasionalFluid Leaks $350–$1,800 to fix

Can't confirm for this car

4WD variants of the DA62 Every use an electronically controlled rear coupling unit sealed with rubber O-rings and seals that harden and leak with age. Seal failure causes coupling fluid loss, which leads to 4WD engagement failure or, in advanced cases, coupling overheating and internal damage. The fault is frequently missed at WOF as the coupling is on the underside and 4WD function is not routinely tested.

Symptoms to notice

  • 4WD warning light on dashboard or failure to engage 4WD
  • Oil residue or drips from the rear coupling or propeller shaft area
  • Shuddering or binding under tight turns in 4WD mode

What to check

  1. Inspect the rear coupling from underneath for oil weeping or staining on the surrounding area.
  2. On 4WD models, engage 4WD mode and confirm normal operation.
  3. Check coupling fluid level if an inspection plug is accessible.

Where to look: Rear coupling unit at rear of propeller shaft, underside

Ask the seller

  • “Has the 4WD system been tested recently and does it engage correctly?”
  • “Has any 4WD warning light appeared?”

Suzuki Every faults in detail

Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

CVT Belt Judder Under Light Throttle LoadMajor · TransmissionK6A Turbo Oil Feed Line Clogging Leading to Turbo Bearing FailureCritical · Engine

What these repairs cost on other cars

Some of the Suzuki Every’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Suzuki models

Suzuki Swift41 documented faultsSuzuki Escudo29 documented faultsSuzuki Jimny27 documented faultsSuzuki Ignis14 documented faultsSuzuki Hustler11 documented faultsSuzuki Carry10 documented faults

Suzuki Every buyer questions

Is the Suzuki Every reliable?

Like any used car, it depends on the specific example and its service history. Across the 14 documented faults for the Suzuki Every, the recurring problem areas are engine, suspension, and body & rust. A Suzuki Every with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.

What are the most common problems with a used Suzuki Every?

We've catalogued 14 known faults for the Suzuki Every, covering engine, suspension, and body & rust. All 14 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Suzuki Every?

Most single repairs on the Suzuki Every fall between $400–$1,600 at NZ independent-workshop rates. Some of the 14 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.

Should I get a pre-purchase inspection on a Suzuki Every?

Yes. A Suzuki Every inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $24.90 far less than the cost of missing one of the faults on this page.