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Fluid Pressure Test

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Suzuki XL-7, 2004 Suzuki Vitara, 2004 Suzuki Grand Vitara, 2003 Suzuki XL-7, and 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.
  1. Before fluid pressure test, ensure fuel tank is full and spare tire, tools, jack and jack handle are installed. No other load should be placed in vehicle. Park vehicle on level ground. Place weight in rear cargo area so rear axle weight is as specified. See REAR CARGO AREA & REAR AXLE WEIGHT REQUIREMENTS  table. See Fig 1.
    REAR CARGO AREA & REAR AXLE WEIGHT REQUIREMENTS

    Weight In Rear Cargo Area - Lbs. (kg) Rear Axle Weight - Lbs. (kg)
    Grand Vitara & Vitara
    441 (200) 1764 (800)
    XL-7
    220 (100) 1984 (900)
  2. Connect fluid pressure gauge to left front and left rear brake bleeder valves. Bleeder plug adapters are provided for 7 mm and 8 mm brake bleeder valves. See Fig 1. These are manufacturer's part numbers for special tools:

    Special Tools

    • (A) 09956-02310 (Fluid pressure gauge).
    • (B) 09952-46510 (Adapter for 8 mm bleeder plug).
    • (C) 09952-36311 (Adapter for 7 mm bleeder plug - Grand Vitara & Vitara).
    • (C) 09952-48320 (Adapter for 7 mm bleeder plug - XL-7).
    • (D) 55473-82030 (Spare bleeder plug).
    Fig 1: Preparing Vehicle For Fluid Pressure Test Of Load Sensing Proportioning Valve
    G00294411Courtesy of SUZUKI OF AMERICA CORP.
  3. Depress brake pedal gradually until fluid pressure at front brake is 1138 psi (80 kg/cm2 ). 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 (kg/cm2 )
    Grand Vitara 640-1038 (45-73)
    Vitara
    3-Door Model 853-1038 (60-73)
    5-Door Model 640-1038 (45-73)
    XL-7 925-1067 (65-75)
    (1) With front brake pressure of 1138 psi (80 kg/cm2 ).
  4. Depress brake pedal gradually until front brake fluid pressure is 1422 psi (100 kg/cm2 ). 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 (kg/cm2 )
    Grand Vitara 711-1138 (50-80)
    Vitara
    3-Door Model 925-1138 (65-80)
    5-Door Model 711-1138 (50-80)
    XL-7 1038-1181 (73-83)
    (1) With front brake pressure of 1422 psi (100 kg/cm2 ).
  5. Disconnect and cap brake line connecting master cylinder secondary side to 4-way joint at master cylinder. Install and tighten plug (09956-02210) at master cylinder secondary port. See Fig 2. Depress brake pedal until front brake fluid pressure is 1422 psi (100 kg/cm2 ). Check corresponding pressure of rear brakes. If rear brake fluid pressure is 1351-1422 psi (95-100 kg/cm2 ), front fail-safe system is functioning properly.
  6. When test is complete, remove special tools and bleed brake system. Ensure LSPV spring mounting bracket bolt is tightened to specification and test brake system.
Fig 2: Installing Plug In Master Cylinder Secondary Port
G00294412Courtesy of SUZUKI OF AMERICA CORP.
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