GENERAL

Technical Bulletin
Division: Automotive Section Title: Engine
Category: Technical TSB No. TS 05 11094

SUBJECT: SERVICE MANUAL UPDATE FOR DTC P0420 AND/OR (P0430 V6)
INSPECTION AND TROUBLESHOOTING
MODEL(S): SWIFT (SW413), ESTEEM (SY416/SY418), AERIO (RH420/RH423),
VITARA (SQ420/SQ625), GRAND VITARA (SQ625) AND XL-7 (JA627)
YEAR: 1996-2005

CONDITION: Service Manual update to the diagnostic flow chart for DTC P0420 and/or (P0430
V6) Catalyst System Efficiency Below Threshold described as “DTC P0420
INSPECTION” OR “DTC Troubleshooting” in the following Service Manuals.

CAUSE: The Service Manual is not clear as to which catalytic converters should be
replaced if a P0420 and/or (P0430 V6) DTC occurs.

CORRECTION: Please update your Service Manual according to the attached sheets.

Technical Service Department

Dealership Circulation - Initial and file:

Service Manager Parts Manager Service Advisor Technicians

Suzuki bulletins are intended for use by professional technicians, NOT a “do-it-yourselfer.” They are written to inform these technicians of condi-
tions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians
have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that
the bulletin applies to your vehicle, or that your vehicle will have that condition. See your authorized Suzuki dealer for information on whether
your vehicle may benefit from the information. Suzuki reserves the right to change technical specifications at any time without prior notice.
 AFFECTED SERVICE MANUALS
SWIFT
CORRESPONDING
MANUAL NAME PART NUMBER
PAGE
1996 SWIFT SUPPLEMENTARY
99501-51G10-33E P.6-93
SERVICE MANUAL
1998 SWIFT SUPPLEMETARY
99501-51G30-33E P.6-1-85
SERVICE MANUAL
2000 SWIFT SERVICE MANUAL 99500-51G10-33E
P.6-1-87
2001 SWIFT SERVICE MANUAL 99500-51G20-33E

ESTEEM
CORRESPONDING
MANUAL NAME PART NUMBER
PAGE
1996 ESTEEM SUPPLEMENTARY
99501-60G00-33E P.6-94
SERVICE MANUAL
1998 ESTEEM SUPPLEMENTARY
99501-60G20-33E P.6-89
SERVICE MANUAL
P.6-92
1999/2000 ESTEEM SERVICE MANUAL 99500-60G10-33E
(G16 ENGINE),
P.6-1-86
2001 ESTEEM SERVICE MANUAL 99500-60G20-33E (J18 ENGINE)
P.1-118
(G16 ENGINE),
2002 ESTEEM SERVICE MANUAL 99500-60G30-33E
P.1-285
(J18 ENGINE)

AERIO
CORRESPONDING
MANUAL NAME PART NUMBER
PAGE
2002 AERIO SERVICE MANUAL 99500-54G00-33E P.1-111

2003 AERIO SERVICE MANUAL 99500-54G10-33E P.1-112

2004 AERIO SERVICE MANUAL 99500-54G20-33E P.1-110

2005 AERIO SERVICE MANUAL 99500S54G30-33E P.1A-108
VITARA/GRAND VITARA/XL-7
CORRESPONDING
MANUAL NAME PART NUMBER
PAGE

1999 SQ416/SQ420 SERVICE MANUAL 99500-65D00-33E P.6-93

1999 SQ625 SERVICE MANUAL 99500-67D00-33E P.6-113

P.6-93
2000 SQ416/SQ420/SQ625 (G16/J20 ENGINE),
99500-65D10-33E
SERVICE MANUAL P.6-1-113
(H25 ENGINE)
P.6-92
2001 SQ416/SQ420/SQ625 (G16/J20 ENGINE),
99500-65D20-33E
SERVICE MANUAL P.6-1-106
(H25 ENGINE)
2001 JA627 SERVICE MANUAL 99500-52D00-33E P.1-104 and -106

P.1-149
2002 VITARA / GRAND VITARA (G16/J20 ENGINE),
99500-65D30-33E
SERVICE MANUAL P.1-324
(H25 ENGINE)

2002 GRAND VITARA XL-7

99500-52D10-33E P.1-123 and -125
SERVICE MANUAL
2003 VITARA SERVICE MANUAL 99500-65D40-33E P.1A-103
P.1A-116
2003 GRAND VITARA / XL-7 (H25 ENGINE),
99500-52D20-33E
SERVICE MANUAL P.1A-296 and –298
(H27 ENGINE)

2004 VITARA SERVICE MANUAL 99500-65D50-33E P.1A-105

P.1A-107
2004 GRAND VITARA / XL-7 (H25 ENGINE),
99500-52D30-33E
SERVICE MANUAL P.1A-282 and -284
(H27 ENGINE)
P.1A-107
2005 GRAND VITARA / XL-7 (H25 ENGINE),
99500S52D40-33E
SERVICE MANUAL P.1A-283 and -285
(H27 ENGINE)
SWIFT
The correction of DTC P0420 INSPECTION in ENGINE DIAGNOSIS for SWIFT (Refer to the corresponding
page.)
CURRENT REVISED
Replace three way catalytic converter. For 96-01MY G10 engine with WU-TWC, replace both
exhaust pipe and catalyst case set with new ones.

or
For 96-01MY G10 engine without WU-TWC, replace
only exhaust pipe with new one.

For 96-01MY G13 engine without WU-TWC, replace

only exhaust pipe with new one.

or
For 97-01MY G13 engine with WU-TWC, replace both
exhaust manifold and exhaust pipe No.2 with new
ones.
NOTE:
Parts, exhaust pipe #2 , includes three way catalytic converter (TWC).
Parts, exhaust manifold, includes warm up three way catalytic converter (WU-TWC).
Parts, exhaust pipe, includes three way catalytic converter (TWC).

ESTEEM
The correction of DTC P0420 INSPECTION or TROUBLESHOOTING in ENGINE DIAGNOSIS for
ESTEEM (Refer to the corresponding page.)

CURRENT REVISED
Replace three way catalytic converter. Replace both exhaust pipe No.1 and exhaust pipe No.2
with new ones.
or
Replace both exhaust manifold and exhaust pipe No.2
with new ones.
NOTE:
Parts, exhaust pipe No.1 (or exhaust manifold), includes warm up three way catalytic converter (WU-TWC)
Part, exhaust pipe No.2, includes three way catalytic converter (TWC).
AERIO
The correction of DTC P0420 TROUBLESHOOTING in General Information and Diagnosis for AERIO
(Refer to the corresponding page.)

CURRENT REVISED
Replace three way catalytic converter. Replace both catalyst case and exhaust pipe No.1 with
new ones.
NOTE:
Parts, catalyst case and exhaust pipe No.1, include warm up three way catalytic converter (WU-TWC) and
three way catalytic converter (TWC), respectively.
VITARA (SQ416/SQ420)
The correction of DTC P0420 TROUBLESHOOTING in Engine Diagnosis for G.Vitara G16/J20 engine.
(Refer to the corresponding page.)
CURRENT REVISED
Replace three way catalytic converter. Replace exhaust pipe No.2 and also exhaust pipe
No.1 with new one(s) if WU-TWC is equipped.
NOTE:
Parts, exhaust pipe No.1 and exhaust pipe No.2, include warm up three way catalytic converter
(WU-TWC) and three way catalytic converter (TWC), respectively.

VITARA(SQ625)/GRAND VITARA(SQ625)/XL-7(JA627)
The correction of DTC P0420/0430 TROUBLESHOOTING in Engine General Information and Diagnosis for
H25 and H27 engine. (Refer to the corresponding page.)
CURRENT REVISED
Replace three way catalytic converter. In DTC P0420, replace both exhaust pipe No.2
and exhaust manifold (Bank1) with new ones.
or
In DTC P0430, replace both exhaust pipe No.2
and exhaust manifold (Bank2) with new ones.
NOTE:
Parts, exhaust manifold and exhaust pipe No.2, include warm up three way catalytic converter (WU-TWC)
and three way catalytic converter (TWC), respectively.