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Pressure Test

WARNING: This page does not describe the selected car, but rather 10 other vehicles, including the 2002 Suzuki XL-7, 2002 Suzuki Vitara, 2002 Suzuki Grand Vitara, 2002 Suzuki Esteem, and 2002 Suzuki Aerio. However, it is still accessible from the selected car via links, so may be relevant.
  1. Park vehicle on level ground. On Grand Vitara and Vitara, place a load of 441 lbs. (200kg.) in rear cargo area, so rear axle weight is 1764 lbs (800kg.). On XL-7, place a load of 220 lbs. (100kg.) in rear cargo area, so rear axle weight is 1984 lbs. (900kg.).
  2. On all models, install special tools to front and rear brakes. Follow tool manufacturer's instructions. For brake with 10 mm bleeder plug, install special tool (A). For brake with 8 mm bleeder plug, install special tool (A), except attachment and special tool (B). For brake with 7 mm bleeder plug, install special tool (A), except attachment and special tool (C).

    Special Tools

    • (A) 09956-02310 (Fluid pressure gauge)
    • (B) 09952-46510 (Attachment for 8 mm bleeder plug)
    • (C) 09952-36310 (Attachment for 7mm bleeder plug)
    • (D) 55473-82030 (Air bleeder supplied as a spare part)
  3. Depress brake pedal gradually until front brake fluid pressure is 1138 psi (8000 kPa). Check corresponding pressure of rear brakes. See INITIAL FLUID PRESSURE TEST  table. If pressure is not as specified, adjust linkage. See ADJUSTMENT .
    INITIAL FLUID PRESSURE TEST

    Application (1) Rear Brake Pressure PSI (kPa)
    Grand Vitara & Vitara
    3-Door Model 853-1038 (6000-7300)
    5-Door Model 640-1038 (4500-7300)
    XL-7 925-1066 (6500-7500)
    (1) With front brake pressure of 1138 psi (8000 kPa).
  4. Depress brake pedal gradually until front brake fluid pressure is 1422 psi (10,000 kPa). Check corresponding pressure of rear brakes. See SECOND FLUID PRESSURE TEST  table. If pressure is not as specified, adjust linkage. See ADJUSTMENT .
    SECOND FLUID PRESSURE TEST

    Application (1) Rear Brake Pressure PSI (kPa)
    Grand Vitara & Vitara
    3-Door Model 924-1138 (6500-8000)
    5-Door Model 711-1138 (5000-8000)
    XL-7 1039-1180 (7300-8300)
    (1) With front brake pressure of 1422 psi (10,000 kPa).
  5. Disconnect brake pipe connecting between master cylinder secondary side and 4-way joint from master cylinder. Tighten plug from special tool (A) into master cylinder port. See Fig 1. Depress brake pedal gradually until front brake fluid pressure is 1422 psi (10,000 kPa). Check corresponding pressure of rear brakes. If rear brake fluid pressure is 1422 psi (10,000 kPa), front fail-safe system functions properly.
  6. When test is complete, remove special tools and bleed brake system.
Fig 1: Installing Special Tool In Master Cylinder
G00275696Courtesy of SUZUKI OF AMERICA CORP.
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