Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Pressure Limit (Isolation/Dump) Valve

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INSPECTION



See Figure 1

  1. Ensure the ignition switch is turned OFF .
  2.  
  3. Detach the wiring harness connector from the pressure limit valve.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Measure the resistance between the ISO and GND terminals, the DUMP and GND terminals, and the RESET terminal and valve body-replace the valve if the resistance values are not within the specified ranges

  1. Using a Digital Volt-Ohmmeter (DVOM) set on the ohmmeter function, measure the resistance between valve terminals ISO and GND, terminals DUMP and GND, and between the valve body and terminal RESET. The resistance between terminals ISO and GND should register 3-6 ohms at 68°F (20°C). The resistance between terminals DUMP and GND should be 1-3 ohms at 68°F (20°C). The resistance between the valve body and terminal RESET should register infinite resistance (no continuity). If the resistances were not as indicated, replace the valve.
  2.  
  3. Reaatch the wiring harness connector to the valve.
  4.  

REMOVAL & INSTALLATION



2-Door Models

See Figure 2

The pressure limit valve is mounted on the master cylinder on 2-door models.

  1. Remove the master cylinder ( along with the pressure limit valve) from the brake power booster.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: On 2-door models, the pressure limit valve is mounted on the underside of the master cylinder

  1. Remove the brake fluid lines attaching the valve to the master cylinder.
  2.  
  3. Remove the pressure limit valve from the master cylinder.
  4.  


WARNING
Never attempt to disassemble the pressure limit valve assembly. If the valve is found to be defective, replace the entire unit with a new one.

To install:
  1. Install the valve on the master cylinder and reattach the brake fluid lines. Tighten the brake fluid line fittings to 124-159 inch lbs. (14-18 Nm).
  2.  
  3. Install the master cylinder, as described earlier in this section.
  4.  

4-Door Models

The pressure limit valve is mounted next to the battery on 4-door models.

  1. Disconnect the brake line fittings at the valve, then plug the brake lines. Protect the surrounding paintwork from brake fluid spillage.
  2.  
  3. Detach the wiring harness connector from the valve.
  4.  
  5. Remove the bolts holding the valve to the bracket.
  6.  

Do not touch the electrical connectors or pins; do not allow them to contact brake fluid. If contaminated with brake fluid, clean them with water followed by isopropyl alcohol.

  1. Carefully remove the valve from the vehicle.
  2.  


WARNING
Never attempt to disassemble the pressure limit valve assembly. If the valve is found to be defective, replace the entire unit with a new one.

To install:
  1. Place the valve in position and install the retaining bolts. Tighten the bolts to 159-21 inch lbs. (18-28 Nm).
  2.  
  3. Reattach the wiring harness connector to the valve.
  4.  
  5. Install the brake lines, then tighten the fittings to 124-159 inch lbs. (14-18 Nm).
  6.  
  7. Bleed the brake system, as described earlier in this section.
  8.  

 
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