Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Heater Core

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REMOVAL & INSTALLATION



Samurai Models

See Figure 1

  1. Remove the heater system blower motor, as described earlier in this section.
  2.  
  3. Set the heater assembly case on its side on a clean, flat work surface.
  4.  
  5. Loosen the heater assembly screws that hold the two assembly case halves together, then lift the upper case half off of the lower case half.
  6.  
  7. Remove the heater core from the bottom case half.
  8.  

To install:
  1. Set the heater core in the lower case half.
  2.  
  3. Install the upper case half onto the lower case half, ensuring that all air control flap pins are installed in the proper holes.
  4.  
  5. Install and tighten the case half attaching bolts securely.
  6.  
  7. Install the blower motor and heater case in the vehicle.
  8.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 1 through 4

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a large, clean catch pan.
  4.  
  5. Remove the instrument panel from the vehicle, as described in General Information & Maintenance 0.
  6.  
  7. Remove the instrument panel center support from the firewall.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the air distribution (ducting) system



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the heater case assembly, showing the heater core position

  1. Detach and label all wiring harness connectors from the heater case.
  2.  
  3. Disconnect all of the cables from the heater case.
  4.  
  5. Detach the two heater hoses from the heater case.
  6.  
  7. Remove the defroster duct and speedometer cable retaining bracket from the heater case.
  8.  
  9. Remove the grommets and floor duct from the case.
  10.  
  11. Open the hood, then remove the heater case-to-firewall mounting nuts from the engine side of the firewall.
  12.  
  13. Remove the two mounting bolts from inside the passengers' compartment, then remove the case from the vehicle.
  14.  
  15. Loosen the heater core retaining bolts, then slide the heater core out of the heater case.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: To separate the heater case assembly from the firewall, remove the two nuts from the engine compartment, and the two bolts from inside the passengers' compartment



Click image to see an enlarged view

Fig. Fig. 4: Remove the heater core retaining fasteners, then slide the core out of the heater case assembly

To install:
  1. Install the heater core in the heater case, then tighten the retaining bolts securely.
  2.  
  3. Position the heater case in the vehicle, against the firewall, and install the mounting bolts. Tighten them securely.
  4.  
  5. From the engine compartment, install and tighten the heater case mounting nuts securely.
  6.  
  7. Install the floor duct and grommets, then reattach the speedometer cable retaining bracket and defroster duct to the heater case.
  8.  
  9. Reattach all of the cables, hoses and wiring harness connectors to the heater case.
  10.  
  11. Install the instrument panel center bracket, ensuring to tighten the bolts securely.
  12.  
  13. Install the instrument panel.
  14.  
  15. Fill the engine cooling system, as described in General Information & Maintenance .
  16.  
  17. Connect the negative battery cable, then start the engine and ensure that the heater system works properly.
  18.  

 
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