Heater Unit Removal and Installation: Removal

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 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.

Disconnect negative (-) cable at battery.
Disable air bag system. Refer to DISABLING & ACTIVATING AIR BAG SYSTEM .
Drain engine coolant and disconnect heater hoses (1) from heater unit.

Fig 1: Disconnecting Heater Hoses From Heater Unit
Courtesy of SUZUKI OF AMERICA CORP.
Remove instrument panel referring to INSTRUMENT PANEL REMOVAL AND INSTALLATION .
Remove blower unit. Refer to BLOWER UNIT REMOVAL AND INSTALLATION .
Disconnect rear duct from heater unit.
Disconnect air flow control actuator lead wire (1) at coupler and temperature control actuator lead wire (2) at coupler (2).
Remove SDM (3).

Fig 2: Removing SDM
Courtesy of SUZUKI OF AMERICA CORP.
Remove heater unit.

Fig 3: Removing Heater Unit
Courtesy of SUZUKI OF AMERICA CORP.
Remove temperature control actuator from heater unit.
Remove heater core pipe clamp (1) and heater core bracket (2).

Fig 4: Removing Heater Core Pipe Clamp
Courtesy of SUZUKI OF AMERICA CORP.
Pull out heater core from heater unit.

Fig 5: Pulling Out Heater Core
Courtesy of SUZUKI OF AMERICA CORP.