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Home >> Suzuki >> 2005 >> XL-7 EX, 4WD >> Repair and Diagnosis >> Engine Performance >> System >> Aux. Emission Control Devices >> H25 Engine >> Diagnostic Information and Procedures >> Evaporative Emission System Leak Inspection >> Pressurization Test
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Pressurization Test

WARNING: Use the nitrogen gas. If other kind of gas is used instead of the nitrogen gas, the gasoline may ignite and explode.
NOTE: A large difference between the vehicle temperature and shop temperature will seriously affect the accuracy of the tests. Always allow enough time for the vehicle's temperature to adjust to the shop temperature.
If the pressure regulator is replaced, perform the calibration referring to "OUTPUT PRESSURE CALIBRATION " in this instructions.
  1. Connect the red battery clip from the tester to the positive battery terminal, and then connect the black battery clip from the tester to chassis ground.
    NOTE: The vehicle battery must be fully charged for optimum tester performance.
  2. Turn the NITROGEN/SMOKE valve (1) on the front control panel to NITROGEN.
    NOTE:
    • Decide which test orifice to use by referring to the table shown below.
      TEST ORIFICE IDENTIFICATION TABLE

      Vehicle Specification Test Orifice
      Before 2003 Model Year 0.040 in. (1.0 mm) orifice
      On and after 2003 Model Year 0.020 in. (0.5 mm) orifice
    • Unwind the nitrogen/smoke hose completely from the bracket to optimize the tester's performance.
  3. Connect the nitrogen/smoke hose (2) to the correct test orifice (3) on the bottom-front of the tester.
  4. Press and release the remote switch (4) to activate the tester.
    Fig 1: Releasing Remote Switch To Activate Tester
    G04097623Courtesy of SUZUKI OF AMERICA CORP.
  5. Position the red flag (1) on the flowmeter to align with the floating indicator (2). When the red flag is set, press and release the remote switch to deactivate the tester.
    Fig 2: Positioning Red Flag On Flowmeter To Align With Floating Indicator
    G04097624Courtesy of SUZUKI OF AMERICA CORP.
  6. Disconnect the nitrogen/smoke hose from the test orifice.
  7. Connect the nitrogen/smoke hose onto the fuel cap adapter (1).
  8. Remove fuel cap, and then install fuel cap adapter onto the fuel filler neck.
  9. Install fuel cap (2) onto the fuel cap adapter.
    NOTE: Connections must be tight and leak-free.
    Fig 3: Installing Fuel Cap Onto Fuel Cap Adapter
    G04097625Courtesy of SUZUKI OF AMERICA CORP.
  10. Turn the ignition switch ON leaving the engine OFF.
    WARNING: To prevent personal injury and equipment damage, tests with Evaporative Emission System Tester are performed with the engine OFF.
  11. Using the scan tool, close the canister vent valve. The evaporative emission system should now be sealed and ready to be tested.

    Special tool 

    : SUZUKI scan tool 

  12. Press and release the remote switch to activate the nitrogen flow and fill the system. Watch the flowmeter's indicator until it stabilizes.
    NOTE:
    • The remote switch operates in a push ON, push OFF manner.
    • Larger volume fuel tanks and/or those with lower fuel levels may require several minutes to fill with nitrogen.
  13. Compare the stable floating indicator position to the red flag as follows.
    1. If indicator floats above the red flag, the result is UNACCEPTABLE. Locate and repair a leak referring to "EVAPORATIVE EMISSION SYSTEM SMOKE TEST ".
    2. If indicator floats below the red flag, the result is ACCEPTABLE. Test is completed.
    Fig 4: Comparing Stable Floating Indicator Position To Red Flag
    G04097626Courtesy of SUZUKI OF AMERICA CORP.
  14. Press and release the remote switch to deactivate the tester.
  15. Charge the battery as necessary.
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