Service Manual Update For DTC P0420 And/Or (P0430 V6) Inspection And Troubleshooting (TS 05 11094)

Publication date: 2004-11-08
Reference number: TS 05 11094

SERVICE MANUAL UPDATE FOR DTC P0420 AND/OR (P0430 V6) INSPECTION AND TROUBLESHOOTING

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 05 11094, Date of Issue: November 09, 2004

SUZUKI:	1996-2005 Swift (SW413), Esteem (SY416/SY418), Aerio (RH420/RH423), Vitara (SQ420/SQ625), Grand Vitara (SQ625) and XL-7 (JA627)
SECTION:	ENGINE

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.

AFFECTED SERVICE MANUALS

AFFECTED SERVICE MANUALS - SWIFT

Manual Name	Part Number	Corresponding Page
1996 SWIFT SUPPLEMENTARY SERVICE MANUAL	99501-51G10-33E	P.6-93
1998 SWIFT SUPPLEMETARY SERVICE MANUAL	99501-51G30-33E	P.6-1-85
2000 SWIFT SERVICE MANUAL	99500-51G10-33E	P.6-1-87
2001 SWIFT SERVICE MANUAL	99500-51G20-33E	P.6-1-87

AFFECTED SERVICE MANUALS - ESTEEM

Manual Name	Part Number	Corresponding Page
1996 ESTEEM SUPPLEMENTARY SERVICE MANUAL	99501-60G00-33E	P.6-94
1998 ESTEEM SUPPLEMENTARY SERVICE MANUAL	99501-60G20-33E	P.6-89
1999/2000 ESTEEM SERVICE MANUAL	99500-60G10-33E	P.6-92 (G16 ENGINE), P.6-1-86 (J18 ENGINE)
2001 ESTEEM SERVICE MANUAL	99500-60G20-33E	P.6-92 (G16 ENGINE), P.6-1-86 (J18 ENGINE)
2002 ESTEEM SERVICE MANUAL	99500-60G30-33E	P.1-118 (G16 ENGINE), P.1-285 (J18 ENGINE)

AFFECTED SERVICE MANUALS - AERIO

Manual Name	Part Number	Corresponding 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

AFFECTED SERVICE MANUALS - VITARA/GRAND VITARA/XL-7

Manual Name	Part Number	Corresponding Page
1999 SQ416/SQ420 SERVICE MANUAL	99500-65D00-33E	P.6-93
1999 SQ625 SERVICE MANUAL	99500-67D00-33E	P.6-113
2000 SQ416/SQ420/SQ625 SERVICE MANUAL	99500-65D10-33E	P.6-93 (G16/J20 ENGINE), P.6-1-113 (H25 ENGINE)
2001 SQ416/SQ420/SQ625 SERVICE MANUAL	99500-65D20-33E	P.6-92 (G16/J20 ENGINE), P.6-1-106 (H25 ENGINE)
2001 JA627 SERVICE MANUAL	99500-52D00-33E	P.1-104 and -106
2002 VITARA / GRAND VITARA SERVICE MANUAL	99500-65D30-33E	P.1-149 (G16/J20 ENGINE), P.1-324 (H25 ENGINE)
2002 GRAND VITARA XL-7 SERVICE MANUAL	99500-52D10-33E	P.1-123 and -125
2003 VITARA SERVICE MANUAL	99500-65D40-33E	P.1A-103
2003 GRAND VITARA / XL-7 SERVICE MANUAL	99500-52D20-33E	P.1A-116 (H25 ENGINE), P.1A-296 and -298 (H27 ENGINE)
2004 VITARA SERVICE MANUAL	99500-65D50-33E	P.1A-105
2004 GRAND VITARA / XL-7 SERVICE MANUAL	99500-52D30-33E	P.1A-107 (H25 ENGINE), P.1A-282 and -284 (H27 ENGINE)
2005 GRAND VITARA / XL-7 SERVICE MANUAL	99500S52D40-33E	P.1A-107 (H25 ENGINE), P.1A-283 and -285 (H27 ENGINE)

SWIFT

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

CORRECTION DTC P0450 - SWIFT

Current	Revised
Replace three way catalytic converter.	For 96-01 MY G10 engine with WU-TWC, replace both exhaust pipe and catalyst case set with new ones.
	or
	For 96-01 MY G10 engine without WU-TWC, replace only exhaust pipe with new one.
	For 96-01 MY G13 engine without WU-TWC, replace only exhaust pipe with new one.
	or
	For 97-01 MY 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.)

CORRECTION OF DTC P0420 - ESTEEM

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.)

CORRECTION OF DTC P0420 - AERIO

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.)

CORRECTION OD DTC P0420 - VITARA (SQ416/SQ420)

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.)

CORRECTION OF DTC P0420/0430 - VITARA(SQ625)/(GRAND VITARA(SQ625)/XL-7(JA627)

Current	Revised
Replace three way catalytic converter.	In DTC P0420, replace both exhaust pipe No.2 and exhaust manifold (Bank 1) with new ones.
	or
	In DTC P0430, replace both exhaust pipe No.2 and exhaust manifold (Bank 2) 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.