Suzuki Aerio, Verona 2002-06

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove:

    The hoses from the heater core pipes in the engine compartment
     
    The seal and the plate
     
    The soundproofing panel
     
    The bolt for the heat exchanger
     
    The mounting brackets for the pipes
     

  6.  
  7. Position plenty of paper under the heat exchanger and around the pipes.
  8.  
  9. Drain the coolant into a suitable container.
  10.  
  11. Detach the pipes and move them out of the way.
  12.  
  13. Pull out the heat exchanger.

    Click image to see an enlarged view

    Fig. Heater core

  14.  

To install:

  1. Install:

    The upper pipe
     
    The striker plate using round-nosed pliers.
     
    The catch using a pair of pliers.
     
    The lower pipe
     
    The striker plate using round-nosed pliers.
     
    The striker plate using round-nosed pliers.
     
    The seal and the plate
     
    The heating loops in the engine compartment.
     

  2.  
  3. Start the engine and the heating system.
  4.  
  5. Fill the cooling system.
  6.  
  7. Check that the pipe connectors do not leak.
  8.  
  9. Install the soundproofing panel.
  10.  

Aerio



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Recover refrigerant from A/C system.
    NOTE
    The amount of removed compressor oil must be measured for replenishing compressor oil.

  6.  
  7. Remove suction pipe mounting bolts.
  8.  
  9. Disconnect suction pipe and condenser outlet pipe using special tools 09991-15410 and 09991-15420.
    WARNING
    Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.

  10.  
  11. Drain engine coolant and disconnect heater hoses from heater unit.
  12.  
  13. Remove heater unit mounting nuts.
  14.  
  15. Remove instrument panel as follows:
    1. Disable air bag system.
    2.  
    3. Remove steering column hole cover.
    4.  
    5. Detach steering lower shaft.
    6.  
    7. Remove glove box and hood latch release lever.
    8.  
    9. Remove console box.
    10.  
    11. Remove instrument panel center lower covers.
    12.  
    13. Remove front pillar trims, front pillar lower garnishes, front side sill scuffs and dash side trims.
    14.  
    15. Disconnect instrument panel harness connectors and antenna cable which need to be disconnected for removal for instrument panel.
    16.  
    17. Remove instrument panel ground wire.
    18.  
    19. Remove instrument panel mounting bolts.
    20.  
    21. Remove instrument panel with steering column, steering support member and instrument panel harness.

      Click image to see an enlarged view

      Fig. Instrument panel and mounting bolt locations-Aerio

    22.  

  16.  
  17. Disconnect main harness connector and clamp, air intake control actuator connector and blower motor connector.
  18.  
  19. Remove blower motor relay from blower unit.
  20.  
  21. Remove blower unit from vehicle body.

    Click image to see an enlarged view

    Fig. Exploded view of the heater core, heater housing and related components-Aerio

  22.  
  23. Disconnect couplers from the following parts:

    Temperature control actuator
     
    Air flow control actuator
     
    A/C evaporator inlet air temperature sensor
     
    A/C evaporator outlet air temperature sensor
     
    Blower motor controller
     

  24.  
  25. Remove heater and cooling unit drain hose .
  26.  
  27. Remove heater and cooling unit from vehicle body.
  28.  
  29. Remove the heater core.
  30.  

To install:

  1. Reverse removal procedure to install heater and cooling unit noting the following instructions:
    NOTE
    When installing each part, be careful not to catch any cable or wiring harness.



    Heater core to the heater and cooling unit
     
    Heater and cooling unit into the vehicle
     
    Blower unit
     
    Blower motor relay
     

  2.  
  3. Replenish specified amount of compressor oil to compressor suction side.
  4.  
  5. Evacuate and charge refrigerant.
  6.  
  7. Sufficiently apply compressor oil to fitting surface of O-ring and pipe.
  8.  
  9. Install the instrument panel.
  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

Verona



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the refrigerant.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the instrument panel assembly as follows:
    1. Remove the floor console.
    2.  
    3. Remove the sun sensor by gently prying up on it and disengaging the connector.
    4.  
    5. Remove the tweeter speakers by gently prying up on it and disengaging the connectors.
    6.  
    7. Remove the stereo cassette AM/FM radio by first removing the audio system trim plate, mounting screws and then disengaging the audio system electrical connectors.
    8.  
    9. Remove the instrument cluster dimmer switch assembly.
    10.  
    11. Remove the instrument cluster trim panel.
    12.  
    13. Remove the automatic temperature controls assembly.
    14.  
    15. Remove the instrument cluster.
    16.  
    17. Remove the kick panels.
    18.  
    19. Remove the glove box.
    20.  
    21. Remove the screws and the glove box housing.
    22.  
    23. Disconnect the glove box housing electrical connectors.
    24.  
    25. Remove the knee bolster.
    26.  
    27. Remove the screws and the instrument panel side covers.
    28.  
    29. Remove the screw and instrument panel fuse block.
    30.  
    31. Remove the nuts and the bolts securing the steering column.
    32.  
    33. Disconnect the steering column electrical connector and lower the steering column.
    34.  
    35. Remove the instrument panel bolts below the windshield.
    36.  
    37. Remove the fixing screws securing the instrument panel.
    38.  
    39. Remove the nuts securing the sides of the instrument panel to the body.
    40.  
    41. Disconnect the instrument panel electrical connectors.
    42.  
    43. Remove the instrument panel.
    44.  

  10.  
  11. Remove the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.
  12.  
  13. Loosen the clamp bolts from the suction hose and the liquid evaporator pipe to allow movement of the hose and the pipe.
  14.  
  15. Remove the evaporator drain hose.
  16.  
  17. Compress the heater hose clamps at the fire wall and slide the clamps toward the engine.
  18.  
  19. Remove the 2 heater hoses from the core lines at the fire wall.
  20.  
  21. Remove the screws that secure the A/C module to the fire wall on either side of the heater hoses.
  22.  
  23. Remove the A/C module screw, that is located above the fuel filter, from the engine compartment side of the fire wall.
  24.  
  25. Have an assistant support the A/C module from inside the vehicle. Remove the A/C module screws from the evaporator flange on the engine compartment side of the fire wall. The A/C module will start to drop.
  26.  
  27. Pull the case straight away from the fire wall.
  28.  
  29. Remove the A/C module from the vehicle.
  30.  
  31. Remove the heater core from the A/C module as follows:
    1. Remove the wiring harness from the A/C module.
    2.  
    3. Slide the cable eyelet off the post on the temperature door lever.
    4.  
    5. Remove the mode motor ventilation link.
    6.  
    7. Remove the air inlet case with the screws.
    8.  
    9. Remove the evaporator core case cover.
    10.  
    11. Remove the heater core cover with the screws.
    12.  
    13. Remove the heater core clip and heater core from the case.
    14.  

  32.  

To install:

  1. Install the heater core to the case.
  2.  
  3. Position the A/C module in the vehicle.
  4.  
  5. Slowly raise the A/C module into position and hold it against the fire wall while the screws are installed and tightened from the engine side of the fire wall.
  6.  
  7. Align and install the A/C module screws above the fuel filter and at the evaporator flange. Tighten the A/C module screws to 71 inch lbs. (8 Nm).
  8.  
  9. Install the A/C module screws adjacent to the heater hoses and tighten the A/C module screws to 71 inch lbs. (8 Nm).
  10.  
  11. Install the evaporator drain hose.
  12.  
  13. Install the 2 heater hoses.
  14.  
  15. Slide the heater hose clamps into position.
  16.  
  17. Install the instrument panel assembly.
  18.  
  19. Install new O-rings on the suction hose and the liquid evaporator pipe at the fire wall and put the pipes back in place.
  20.  
  21. Install the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall. Tighten the suction hose and the liquid evaporator pipe retaining nuts to 89 inch lbs. (10 Nm).
  22.  
  23. Refill the cooling system.
  24.  
  25. Recharge the A/C system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  30.  

 
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