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Home/Suzuki/Vitara/Suzuki Vitara I (2003-2004)/Repair manual/Automatic HVAC System/Heater & Ventilation: Removal & Installation
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Heater & Ventilation: Removal & Installation Suzuki Vitara I

Automatic HVAC System 17 illustrations ~715 words

INSTALLATION

  1. Reverse removal procedure for installation.
  2. Connect fresh air control cable. See «HEATER CONTROL CABLES REMOVAL & INSTALLATION»(ref-182730-S26813938012005080900000) .
  3. Enable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .

Scheme 17

Scheme 17: REMOVAL
Scheme 17: REMOVAL

Scheme 18

Scheme 18
Scheme 18
  1. Disconnect negative (-) cable at battery.
  2. Disable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  3. Remove ECM with bracket from blower motor unit.
  4. Disconnect harness clamps from dash panel.
  5. Loosen 3 nuts (1) fastening blower unit (2).
  6. Disconnect blower motor lead wire at coupler (2).
  7. Remove blower motor (3) from blower unit (1).
  1. Reverse removal procedure for installation.
  2. Enable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .

Scheme 19

Scheme 19: HEATER BLOWER MOTOR INSPECTION
Scheme 19: HEATER BLOWER MOTOR INSPECTION

Scheme 20

Scheme 20
Scheme 20
  1. Check continuity between terminal to terminal as shown in the figure. If check results are continuity, proceed to next operation check. If not, replace.
  2. Connect battery to blower motor as shown, then check that the blower motor operates smoothly. Reference current for blower motor 18-24 A at 12 V

Scheme 21

Scheme 21: REMOVAL
Scheme 21: REMOVAL

Scheme 22

Scheme 22
Scheme 22
  1. Disconnect negative (-) cable (2) at battery (1).
  2. Disable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  3. Open glove box, then remove screw (2).
  4. Remove glove box (1).

Scheme 23

Scheme 23
Scheme 23
  1. Disconnect resistor coupler.
  2. Remove heater blower resistor (1) by loosening its fastening screw (2).
  1. Install heater blower resistor with screws.
  2. Enable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  1. Reverse removal procedure for installation.
  2. Enable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  1. Install in reverse order of removal procedure.
  2. Enable air bag system. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .

Scheme 24

Scheme 24: MODE CONTROL SWITCH
Scheme 24: MODE CONTROL SWITCH

Scheme 25

Scheme 25
Scheme 25
  1. Check if continuity exists between each pair of terminals listed below when mode control button is pressed. Mode control switch specification
  2. With battery voltage (+) connected to terminal "I" and (-) to terminal "F", press each mode control button and check if indicator lamp (2) lights.
  3. With battery voltage (+) connected to terminal "A" and (-) to terminal "H", check if illumination lamp (2) lights.

Scheme 26

Scheme 26: REMOVAL
Scheme 26: REMOVAL
  1. Disconnect negative (-) cable at battery.
  2. Disable air bag system. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  3. Remove column hole cover.
  4. Disconnect mode actuator coupler (1).
  5. Disconnect mode actuator rod (2) from heater unit.
  6. Remove heater mode control actuator from heater unit by removing its mounting screw (3).
  1. Install in reverse order of removal procedure.
  2. Enable air bag system. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .

Install in reverse order of removal procedure and fix each cable with clamp in position. See HEATER CONTROL LEVER ASSEMBLY REMOVAL & INSTALLATION .

Scheme 27

Scheme 27: INSTALLATION
Scheme 27: INSTALLATION
  1. After installing control cables be sure that control levers move smoothly and stop at proper position.
  2. Move control lever (1) to FRESH position (2), then push lever fully in arrow direction (4) and fix cable (3) with clamp in position as shown in the figure.

Scheme 28

Scheme 28: HEATER UNIT COMPONENTS
Scheme 28: HEATER UNIT COMPONENTS

REMOVAL

WARNINGFailure to follow the following procedure and WARNING may cause air bag deployment, personal injury, damage to parts, or air bag being unable to deploy. Never rest a steering column assembly on steering wheel with air bag (inflator) module face down and column vertical. When handling the air bag (inflator) modules (driver and passenger), be careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from a height of 91.4 cm (3 feet) or more, never attempt disassembly or repair but replace it with a new one. When grease, cleaning agent. Oil, water, etc. has got onto air bag (inflator) modules (driver and passenger), wipe off immediately with a dry cloth.

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33
  1. Disconnect negative (-) cable at battery.
  2. Disable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  3. Drain engine coolant and disconnect heater hoses (1) from heater unit.
  4. Remove instrument panel. See «REMOVAL»(ref-183958-S26690833152005081900000) , Instrument Panel.
  5. Remove cooling unit (If equipped with air conditioning). See «EVAPORATOR (COOLING UNIT) REMOVAL AND INSTALLATION»(ref-182885-S24427710072005081000000) .
  6. Disconnect rear duct (4) from heater unit.
  7. Disconnect mode actuator lead wire at coupler (1).
  8. Remove A/C controller (2) (If equipped).
  9. Remove SDM (3).
  10. Remove heater unit.
  11. Remove heater core pipe clamps (1) and grommet (2).
  12. Pull out heater core (1) from unit (2).
  1. Install heater unit by reversing removal procedure, noting the following items. When installing each part, be careful not to catch any cable or wiring harness. When installing steering column assembly, see «INSTALLATION»(ref-183959-S36942150922005081900000) , Steering Column.
  2. Install control cables. See «HEATER CONTROL CABLES REMOVAL & INSTALLATION»(ref-182730-S26813938012005080900000) .
  3. Fill engine coolant to radiator.
  4. Enable air bag system, if equipped. See «DISABLING & ACTIVATING AIR BAG SYSTEM»(ref-160470-S11816149552004021000000) .
  5. Evacuate and charge system. See «OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT»(ref-182885-S23346533722005081000000) .
  1. Disconnect negative (-) cable at battery.
  2. Remove front seat.
  3. Remove console box.
  4. Take off carpet till rear duct is totally exposed.
  5. Remove rear duct.

Reverse removal sequence to install rear duct.

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