Pressurization Test

WARNING: Use the nitrogen gas. If other kind of gas is used for 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 EVAPORATIVE EMISSION SYSTEM TESTER OUTPUT PRESSURE CALIBRATION in this instructions.

Connect the red battery clip from the tester to the positive battery terminal, then connect the black battery clip from the tester to chassis ground.
NOTE: The vehicle battery must be fully charged for optimum tester performance.
Turn the NITROGEN/SMOKE valve (1) on the front control panel to NITROGEN.
NOTE: Completely unwind the nitrogen/smoke hose from the bracket to optimize the tester's performance.
Connect the nitrogen/smoke hose (2) to the correct test orifice (3) on the bottom-front of the tester.
Press and release the remote switch (4) to activate the tester.

Fig 1: Pressing Remote Switch To Activate Tester
Courtesy of SUZUKI OF AMERICA CORP.
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: Checking Floating Indicator
Courtesy of SUZUKI OF AMERICA CORP.
Disconnect the nitrogen/smoke hose from the test orifice.
Connect the nitrogen/smoke hose onto the fuel cap adapter (1).
Remove fuel cap, then install fuel cap adapter onto the fuel filler neck.
Install fuel cap (2) onto the fuel cap adapter.
NOTE: Connections must be tight and leak-free.

Fig 3: Connecting Nitrogen/Smoke Hose Onto Fuel Cap Adapter
Courtesy of SUZUKI OF AMERICA CORP.
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.
Close the EVAP canister vent valve as follows.
1. When using SUZUKI scan tool:
  1. Connect SUZUKI scan tool to DLC with ignition switch OFF.
  2. Turn ON ignition switch, clear DTC and select "MISC. TEST" mode on SUZUKI scan tool.
    Special Tool
    1. SUZUKI scan tool
      
      Fig 4: Connecting SUZUKI Scan Tool To DLC With Ignition Switch OFF
      Courtesy of SUZUKI OF AMERICA CORP.
2. When not using SUZUKI scan tool:
  1. Turn ignition switch ON.
  2. Using service wire, ground "G04-5" terminal of ECM connector (valve ON) "B" and unground it (valve OFF) "A".
    
    Fig 5: Identifying Connectors
    Courtesy of SUZUKI OF AMERICA CORP.
Disconnect hose from the outlet nozzle (1) of EVAP leak check module.
Plug outlet nozzle with finger or the rubber plug. The evaporative emission system should now be sealed and ready to be tested.
NOTE: In case that the outlet nozzle of the EVAP leak check module, air would be leaked from the nozzle. Because of the leak, there is a possibility of the misdiagnosis.

Fig 6: Disconnecting Hose From Outlet Nozzle Of EVAP Leak Check Module
Courtesy of SUZUKI OF AMERICA CORP.
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 fashion.
- Larger volume fuel tanks, and/or those with lower fuel levels, may require several minutes to fill with nitrogen.
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 7: Testing Evaporative Emission System Smoke
  Courtesy of SUZUKI OF AMERICA CORP.
Press and release the remote switch to deactivate the tester.
Charge the battery as necessary.