Heater System: Removal & Installation Suzuki Esteem I

REMOVAL & INSTALLATION

1. Disconnect negative battery cable. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect passenger's air bag coupler from steering support member.
2. Remove glove box and support. Remove Electronic Control Module (ECM) harness connector and mounting bolts. Remove ECM. Remove blower motor and blower motor resistor harness connectors. Disconnect fresh air control cable from blower motor case. (Scheme 1) Remove blower motor screws and blower motor from case. To install, reverse removal procedure.

Scheme 1

1. Remove control lever knobs. Remove center garnish mounting screws. Carefully remove center garnish. Remove control cables from heater assembly and blower case. Pull control panel outward sufficiently to disconnect blower motor switch harness connector.
2. Remove control panel from instrument panel. Remove switch. To install, reverse removal procedure. Ensure all control levers operate smoothly. See «ADJUSTMENTS»(ref-360-S29466038852000030800000) .

Removal

1. Disconnect negative battery cable. Drain cooling system. Disconnect heater inlet and outlet hoses at heater pipes. Remove instrument panel and speedometer assembly. See «INSTRUMENT PANEL»(ref-360-S07824768352000030800000).
2. Loosen front door stopper screws. Remove steering column holder. Disconnect heater blower motor and resistor connectors. Loosen heater case nut on engine compartment side. Remove heater assembly. Remove heater blower motor. Remove retaining clips and screws. Separate heater case halves. Remove heater core and rubber seals. (Scheme 3)

Installation

To install, reverse removal procedure. Ensure control cables are correctly routed. (Scheme 2) Refill cooling system and check for leaks.

Scheme 2

Scheme 3

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect negative battery cable. Remove parking brake lever cover. Remove console glove box.
2. Disconnect cigarette lighter harness coupler. Remove console glove box front extension. Disconnect heater blower harness connector. Remove control cables from heater assembly.
3. Remove driver's air bag module. Remove steering wheel. Remove passenger's air bag module. Remove ECM. Remove front pillar trim. Disconnect hood release cable from lock assembly. Detach steering column from instrument panel, and lower to seat.
4. Remove defrost and side ventilator hoses. Disconnect instrument panel electrical connectors at speedometer and switches. Disconnect speedometer cable. Loosen clamps and release wiring harness from instrument panel. Remove instrument panel. To install, reverse removal procedure.