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Heater and Cooling Unit Removal and Installation: Removal

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Failure 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.
  1. Disconnect negative (-) cable at battery.
  2. Disable air bag system.

    For H25 engine model, refer to AIR BAG RESTRAINT SYSTEMS .

    For H27 engine model, refer to AIR BAG RESTRAINT SYSTEMS .

  3. Recover refrigerant by using recovery and recycling equipment. Be sure to follow the instruction manual for the equipment.
  4. Drain engine coolant and disconnect heater hoses (1) from heater unit.
    Fig 1: Draining Engine Coolant
    G00757839Courtesy of SUZUKI OF AMERICA CORP.
  5. Disconnect suction hose (1) and condenser outlet hose (2) by removing attaching bolt (3).
    Fig 2: Disconnecting Suction Hose
    G00757840Courtesy of SUZUKI OF AMERICA CORP.
  6. Remove instrument panel referring to INSTRUMENT PANEL REMOVAL AND INSTALLATION .
  7. Remove blower unit referring to BLOWER UNIT REMOVAL AND INSTALLATION .
  8. Disconnect rear duct from heater unit.
  9. Disconnect wire coupler for A/C evaporator temperature sensor.
  10. Disconnect air flow control actuator lead wire at coupler (1) and temperature control actuator lead wire at coupler (2).
  11. Remove SDM (3).
    Fig 3: Removing SDM
    G00757841Courtesy of SUZUKI OF AMERICA CORP.
  12. Remove heater and cooling unit.
    Fig 4: Removing Heater & Cooling Unit
    G00757842Courtesy of SUZUKI OF AMERICA CORP.
  13. Remove heater core referring to HEATER UNIT REMOVAL AND INSTALLATION .
  14. Remove pipe assembly (1) from expansion valve.
  15. Remove air joint duct (3) from heater and cooling unit.
    Fig 5: Removing Air Joint Duct
    G00757843Courtesy of SUZUKI OF AMERICA CORP.
  16. Remove evaporator (1) with expansion valve (2), and then heater and cooling unit.
Fig 6: Removing Evaporator With Expansion Valve
G00757844Courtesy of SUZUKI OF AMERICA CORP.
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