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.

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.

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.

VEHICLE SPECIFICATION CHART

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.

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: Connecting Nitrogen/Smoke Hose To Correct Test Orifice
Courtesy of SUZUKI OF AMERICA CORP.
Position the red flag (1) on the flow meter 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: Identifying Red Flag On Flow Meter
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, and 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: Identifying Fuel Cap Adapter & Fuel Cap
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.
Using the scan tool, close the canister vent valve.
Special Tool

: SUZUKI scan tool
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.

Fig 4: Identifying Outlet Nozzle
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: The ventilation nozzle of EVAP leak check module must be blocked securely.
The reason for this is that the EVAP system in its design cannot be sealed completely even though the EVAP canister vent valve and the EVAP canister purge valve are both closed because the leak check module internally opens to atmosphere through the leak detection pump. For this reason, if the ventilation nozzle of the leak check module is not blocked completely, nitrogen gas will leak through it possibly resulting in a diagnostic error of EVAP leak.
Press and release the remote switch to activate the nitrogen flow and fill the system. Watch the flow meter'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.
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 5: Identifying Unacceptable & Acceptable Red Flag In Flow Meter
  Courtesy of SUZUKI OF AMERICA CORP.
Press and release the remote switch to deactivate the tester.
Charge the battery as necessary.