Suzuki Vitara, Grand Vitara, XL7 2000-06

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. To disable the air bag system, perform the following procedure:
    1. Position the front wheels so that they are pointing straight ahead.
    2.  
    3. Turn the ignition switch to the LOCK position.
    4.  
    5. In the fuse box, remove the AIR BAG fuse.
    6.  
    7. Under the steering column, locate the contact coil/combination switch assembly-s yellow connector; then, unlock and disconnect the connector.
    8.  
    9. Pull outward on the glove box while pushing the stopper located at both sides and locate the passenger-s side air bag module yellow connector; then, unlock and disconnect the connector.
      NOTE
      With the AIR BAG fuse removed and the ignition switch turned ON; the air bag warning light may be ON; this is normal operation and does not indicate an air bag malfunction.

    10.  

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater core.
  8.  
  9. Remove the instrument panel by performing the following procedure:
    1. Remove the console.
    2.  
    3. Remove the glove box and the column hole cover.
    4.  
    5. Disconnect the electrical connector and cables from the heater housing and blower motor assembly.
    6.  
    7. Remove the steering column.
    8.  
    9. Disconnect the speedometer connector and the speedometer assembly.
    10.  
    11. Remove the hood opener.
    12.  
    13. Disconnect the instrument panel electrical connectors.
    14.  
    15. Remove the instrument panel-to-chassis screws and bolts.
    16.  
    17. Using an assistant, remove the instrument panel.
    18.  

  10.  
  11. If equipped with air conditioning, perform the following procedure:
    1. Discharge and recover the air conditioning refrigerant.
    2.  
    3. If equipped with a G16 or a J20 engine, disconnect the suction pipe and liquid pipe from the air conditioning housing. Plug the openings to prevent contamination.
    4.  
    5. If equipped with an H25 engine, disconnect the compressor suction pipe and receiver/drier outlet pipe from the air conditioning housing. Plug the openings to prevent contamination.
    6.  
    7. Remove the blower motor assembly.
    8.  
    9. Disconnect the thermistor wire coupler.
    10.  
    11. Remove the air conditioning housing.
    12.  

  12.  
  13. Disconnect the rear duct from the heater housing.
  14.  
  15. Disconnect the mode actuator electrical connectors.
  16.  
  17. If equipped, remove the air conditioning controller.
  18.  
  19. If equipped, disconnect and remove the Sensing and Diagnostic Module (SDM) or air bag controller module.
  20.  
  21. Remove the heater housing.
  22.  
  23. Remove the heater core pipe clamps and grommet.
  24.  
  25. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the instrument panel and fasteners-Suzuki Vitara



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing and ventilation ducts-Suzuki Vitara



    Click image to see an enlarged view

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

  26.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the heater core pipe clamps and grommet.
  4.  
  5. Install the heater housing.
  6.  
  7. If equipped, connect and install the Sensing and Diagnostic Module (SDM) or air bag controller module.
  8.  
  9. If equipped, install the air conditioning controller.
  10.  
  11. Connect the mode actuator electrical connectors.
  12.  
  13. Connect the rear duct from the heater housing.
  14.  
  15. If equipped with air conditioning, perform the following procedure:
    1. Install the air conditioning housing.
    2.  
    3. Connect the thermistor wire coupler.
    4.  
    5. Install the blower motor assembly.
    6.  
    7. If equipped with an H25 engine, connect the compressor suction pipe and receiver/drier outlet pipe to the air conditioning housing.
    8.  
    9. If equipped with a G16 or a J20 engine, connect the suction pipe and liquid pipe to the air conditioning housing.
    10.  
    11. Evacuate and charge the air conditioning system.
    12.  

  16.  
  17. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel.
    2.  
    3. Install the instrument panel-to-chassis screws and bolts.
    4.  
    5. Connect the instrument panel electrical connectors.
    6.  
    7. Install the hood opener.
    8.  
    9. Connect the speedometer connector and the speedometer assembly.
    10.  
    11. Install the steering column.
    12.  
    13. Connect the electrical connector and cables to the heater housing and blower motor assembly.
    14.  
    15. Install the glove box and the column hole cover.
    16.  
    17. Install the console.
    18.  

  18.  
  19. Connect the heater hoses to the heater core.
  20.  
  21. Refill the cooling system.
  22.  
  23. To enable the air bag system, perform the following procedure:
    1. Push inward on the glove box while pushing the stopper located at both sides and connect the passenger-s side air bag module yellow connector and lock it.
    2.  
    3. Under the steering column, connect the contact coil/combination switch assembly-s yellow connector.
    4.  
    5. In the fuse box, install the AIR BAG fuse.
    6.  
    7. Turn the ignition switch ON and verify that the AIR BAG warning light flashes 7 times and turns OFF; if the system does not operate as described, perform the Air Bad Diagnostic System Check.
    8.  

  24.  
  25. Connect the negative battery cable.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

Sidekick



Removal & Installation
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a large, clean catch pan.
    CAUTION
    The air bag system must be disarmed before performing service around air bag components or air bag wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary air bag system repairs and/or personal injury.



    Click image to see an enlarged view

    Fig. To disable the air bag system, the air bag fuse must be removed and the yellow air bag module connector disengaged-Suzuki Sidekick, Sidekick Sport and X-90

  4.  
  5. Disable the air bag system by performing the following procedure:
    1. Turn the steering wheel so the front wheels are in the straight-ahead position.
    2.  
    3. Turn the ignition switch to the LOCK position and remove the key.
    4.  
    5. Remove the AIR BAG fuse from the air bag fuse box.
    6.  
    7. Remove the steering wheel side cap and disengage the yellow connector inside the inflator module housing.
    8.  
    9. Remove the glove box, by disengaging both glove box stoppers from each side, then unplug the yellow passenger air bag inflator module connector.
    10.  

  6.  
  7. Remove the steering column as follows:
    1. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch.
    2.  
    3. Open the hood.
    4.  
    5. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft.
    6.  
    7. Loosen all of the steering column-to-firewall and instrument panel brace bolts.
    8.  
    9. If equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch.
    10.  
    11. Remove the steering column from the vehicle.
      CAUTION
      Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical. Personal injury may be the result!

    12.  

  8.  
  9. Remove the center console.
  10.  
  11. Remove the instrument panel by performing the following procedure:
    1. Remove the lower steering column cover by loosening the mounting screws.
    2.  
    3. Remove the glove box.
    4.  
    5. Detach the wiring harness connectors from the heater unit and the blower motor assembly.
    6.  
    7. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster.
    8.  
    9. Remove the hood latch handle.
    10.  
    11. Remove the radio, the heater control panel and the heater control cables from the instrument panel.

      Click image to see an enlarged view

      Fig. Before removing the mounting fasteners, be sure to detach and label all of the wiring harness connectors from the instrument panel-Suzuki Sidekick, Sidekick Sport and X-90



      Click image to see an enlarged view

      Fig. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly--Suzuki Sidekick, Sidekick Sport and X-90



      Click image to see an enlarged view

      Fig. ... then remove the upper cover plates and loosen the remaining mounting fasteners-Suzuki Sidekick, Sidekick Sport and X-90

    12.  
    13. Disconnect and label all wiring harness connectors from the instrument panel.
    14.  
    15. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners
    16.  
    17. Using an assistant, remove the instrument panel. Make sure that all of the cables, wires and hoses are disconnected form the instrument panel.
    18.  

  12.  
  13. Remove the instrument panel center support from the firewall.

    Click image to see an enlarged view

    Fig. Exploded view of the air distribution (ducting) system-Suzuki Sidekick, Sidekick Sport and X-90 similar



    Click image to see an enlarged view

    Fig. Exploded view of the heater case assembly, showing the heater core position-Suzuki Sidekick, Sidekick Sport and X-90 similar

  14.  
  15. Detach and label all wiring harness connectors from the heater case.
  16.  
  17. Disconnect all of the cables from the heater case.
  18.  
  19. Detach the 2 heater hoses from the heater case.
  20.  
  21. Remove the defroster duct and speedometer cable retaining bracket from the heater case.
  22.  
  23. Remove the grommets and floor duct from the case.
  24.  
  25. Open the hood, then remove the heater case-to-firewall mounting nuts from the engine side of the firewall.
  26.  
  27. Remove the 2 mounting bolts from inside the passengers- compartment, then remove the case from the vehicle.
  28.  
  29. Loosen the heater core retaining bolts, then slide the heater core out of the heater case.

    Click image to see an enlarged view

    Fig. To separate the heater case assembly from the firewall, remove the 2 nuts from the engine compartment, and the 2 bolts from inside the passengers- compartment-Suzuki Sidekick, Sidekick Sport and X-90 similar



    Click image to see an enlarged view

    Fig. Remove the heater core retaining fasteners, then slide the core out of the heater case assembly-Suzuki Sidekick, Sidekick Sport and X-90 similar

  30.  

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 by performing the following procedure:
    1. Using an assistant, install the instrument panel. Make sure that all of the cables, wires and hoses are routed properly.
    2.  
    3. Install and tighten the instrument panel mounting screws and bolts.
    4.  
    5. Reattach all wiring harness connectors to the instrument panel.
    6.  
    7. Install the radio, the heater control panel and the heater control cables. Be sure to adjust the heater control cables.
    8.  
    9. Install the hood latch handle.
    10.  
    11. Install the instrument cluster, then connect the cable to the speedometer.

      Click image to see an enlarged view

      Fig. During steering column installation, ensure that the mounting bolts are tightened to the proper torque values-Suzuki Sidekick, Sidekick Sport and X-90 similar

    12.  
    13. Reattach the wiring harness connectors to the heater unit and the blower motor assembly.
    14.  
    15. Install the glove box.
    16.  
    17. Install the lower steering column cover.
    18.  

  14.  
  15. Install the center console.
  16.  
  17. Install the steering column as follows:
    1. Install the steering column in the vehicle.
    2.  
    3. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw.
    4.  
    5. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 18 ft. lbs. (25 Nm).
    6.  
    7. Install and tighten the steering column shaft joint bolt to 18 ft. lbs. (25 Nm).
    8.  
    9. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch.
    10.  

  18.  
  19. Fill the engine cooling system.
  20.  
  21. Enable the air bag system by performing the following procedure:
    1. Engage the passenger air bag inflator module yellow connector. Install glove box.
    2.  
    3. Engage the yellow connector inside the inflator module housing on the driver's air bag. Install the inflator module onto the connector stay.
    4.  
    5. Install the plastic access cover.
    6.  
    7. Turn the ignition switch to the ON position. Verify that the air bag indicator lamp flashes 7 times and then turns OFF. If the lamp does not function as specified, there is a malfunction in the SIR system.
    8.  

  22.  
  23. Connect the negative battery cable, then start the engine and ensure that the heater system works properly.
  24.  

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system into a large, clean catch pan.
    CAUTION
    The air bag system must be disarmed before performing service around air bag components or air bag wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary air bag system repairs and/or personal injury.



    Click image to see an enlarged view

    Fig. To disable the air bag system, the air bag fuse must be removed and the yellow air bag module connector disengaged-Suzuki Sidekick, Sidekick Sport and X-90

  4.  
  5. Disable the air bag system by performing the following procedure:
    1. Turn the steering wheel so the front wheels are in the straight-ahead position.
    2.  
    3. Turn the ignition switch to the LOCK position and remove the key.
    4.  
    5. Remove the AIR BAG fuse from the air bag fuse box.
    6.  
    7. Remove the steering wheel side cap and disengage the yellow connector inside the inflator module housing.
    8.  
    9. Remove the glove box, by disengaging both glove box stoppers from each side, then unplug the yellow passenger air bag inflator module connector.
    10.  

  6.  
  7. Remove the steering column as follows:
    1. Detach the wiring harness connectors from the ignition switch, contact coil and combination switch.
    2.  
    3. Open the hood.
    4.  
    5. Remove the steering column shaft joint bolt, then separate the steering column shaft from the lower steering shaft.
    6.  
    7. Loosen all of the steering column-to-firewall and instrument panel brace bolts.
    8.  
    9. If equipped, remove the shift (key) interlock cable screw. Disconnect the cable from the ignition switch.
    10.  
    11. Remove the steering column from the vehicle.
      CAUTION
      Do not rest the steering column assembly on the steering wheel with the air bag module facing downward and the column vertical. Personal injury may be the result!

    12.  

  8.  
  9. Remove the center console.
  10.  
  11. Remove the instrument panel by performing the following procedure:
    1. Remove the lower steering column cover by loosening the mounting screws.
    2.  
    3. Remove the glove box.
    4.  
    5. Detach the wiring harness connectors from the heater unit and the blower motor assembly.
    6.  
    7. Disconnect the speedometer cable from the speedometer, then remove the instrument cluster.
    8.  
    9. Remove the hood latch handle.
    10.  
    11. Remove the radio, the heater control panel and the heater control cables from the instrument panel.

      Click image to see an enlarged view

      Fig. Before removing the mounting fasteners, be sure to detach and label all of the wiring harness connectors from the instrument panel-Suzuki Sidekick, Sidekick Sport and X-90



      Click image to see an enlarged view

      Fig. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly--Suzuki Sidekick, Sidekick Sport and X-90



      Click image to see an enlarged view

      Fig. ... then remove the upper cover plates and loosen the remaining mounting fasteners-Suzuki Sidekick, Sidekick Sport and X-90

    12.  
    13. Disconnect and label all wiring harness connectors from the instrument panel.
    14.  
    15. Remove the instrument panel mounting screws and bolts. Remove the side cover plates and the instrument panel mounting fasteners from the side of the assembly. Then, remove the upper cover plates and loosen the remaining mounting fasteners
    16.  
    17. Using an assistant, remove the instrument panel. Make sure that all of the cables, wires and hoses are disconnected form the instrument panel.
    18.  

  12.  
  13. Remove the instrument panel center support from the firewall.

    Click image to see an enlarged view

    Fig. Exploded view of the air distribution (ducting) system-Suzuki Sidekick, Sidekick Sport and X-90 similar



    Click image to see an enlarged view

    Fig. Exploded view of the heater case assembly, showing the heater core position-Suzuki Sidekick, Sidekick Sport and X-90 similar

  14.  
  15. Detach and label all wiring harness connectors from the heater case.
  16.  
  17. Disconnect all of the cables from the heater case.
  18.  
  19. Detach the 2 heater hoses from the heater case.
  20.  
  21. Remove the defroster duct and speedometer cable retaining bracket from the heater case.
  22.  
  23. Remove the grommets and floor duct from the case.
  24.  
  25. Open the hood, then remove the heater case-to-firewall mounting nuts from the engine side of the firewall.
  26.  
  27. Remove the 2 mounting bolts from inside the passengers- compartment, then remove the case from the vehicle.
  28.  
  29. Loosen the heater core retaining bolts, then slide the heater core out of the heater case.

    Click image to see an enlarged view

    Fig. To separate the heater case assembly from the firewall, remove the 2 nuts from the engine compartment, and the 2 bolts from inside the passengers- compartment-Suzuki Sidekick, Sidekick Sport and X-90 similar



    Click image to see an enlarged view

    Fig. Remove the heater core retaining fasteners, then slide the core out of the heater case assembly-Suzuki Sidekick, Sidekick Sport and X-90 similar

  30.  

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 by performing the following procedure:
    1. Using an assistant, install the instrument panel. Make sure that all of the cables, wires and hoses are routed properly.
    2.  
    3. Install and tighten the instrument panel mounting screws and bolts.
    4.  
    5. Reattach all wiring harness connectors to the instrument panel.
    6.  
    7. Install the radio, the heater control panel and the heater control cables. Be sure to adjust the heater control cables.
    8.  
    9. Install the hood latch handle.
    10.  
    11. Install the instrument cluster, then connect the cable to the speedometer.

      Click image to see an enlarged view

      Fig. During steering column installation, ensure that the mounting bolts are tightened to the proper torque values-Suzuki Sidekick, Sidekick Sport and X-90 similar

    12.  
    13. Reattach the wiring harness connectors to the heater unit and the blower motor assembly.
    14.  
    15. Install the glove box.
    16.  
    17. Install the lower steering column cover.
    18.  

  14.  
  15. Install the center console.
  16.  
  17. Install the steering column as follows:
    1. Install the steering column in the vehicle.
    2.  
    3. If equipped, connect the cable from the ignition switch, then install the shift (key) interlock cable screw.
    4.  
    5. Install and tighten all of the steering column-to-firewall and instrument panel brace bolts to 18 ft. lbs. (25 Nm).
    6.  
    7. Install and tighten the steering column shaft joint bolt to 18 ft. lbs. (25 Nm).
    8.  
    9. Reattach the wiring harness connectors to the ignition switch, contact coil and combination switch.
    10.  

  18.  
  19. Fill the engine cooling system.
  20.  
  21. Enable the air bag system by performing the following procedure:
    1. Engage the passenger air bag inflator module yellow connector. Install glove box.
    2.  
    3. Engage the yellow connector inside the inflator module housing on the driver's air bag. Install the inflator module onto the connector stay.
    4.  
    5. Install the plastic access cover.
    6.  
    7. Turn the ignition switch to the ON position. Verify that the air bag indicator lamp flashes 7 times and then turns OFF. If the lamp does not function as specified, there is a malfunction in the SIR system.
    8.  

  22.  
  23. Connect the negative battery cable, then start the engine and ensure that the heater system works properly.
  24.  

Vitara And Grand Vitara



Removal & Installation
  1. Disconnect the negative battery cable.
  2.  
  3. To disable the air bag system, perform the following procedure:
    1. Position the front wheels so that they are pointing straight ahead.
    2.  
    3. Turn the ignition switch to the LOCK position.
    4.  
    5. In the fuse box, remove the AIR BAG fuse.
    6.  
    7. Under the steering column, locate the contact coil/combination switch assembly-s yellow connector; then, unlock and disconnect the connector.
    8.  
    9. Pull outward on the glove box while pushing the stopper located at both sides and locate the passenger-s side air bag module yellow connector; then, unlock and disconnect the connector.
      NOTE
      With the AIR BAG fuse removed and the ignition switch turned ON; the air bag warning light may be ON; this is normal operation and does not indicate an air bag malfunction.

    10.  

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater core.
  8.  
  9. Remove the instrument panel by performing the following procedure:
    1. Remove the console.
    2.  
    3. Remove the glove box and the column hole cover.
    4.  
    5. Disconnect the electrical connector and cables from the heater housing and blower motor assembly.
    6.  
    7. Remove the steering column.
    8.  
    9. Disconnect the speedometer connector and the speedometer assembly.
    10.  
    11. Remove the hood opener.
    12.  
    13. Disconnect the instrument panel electrical connectors.
    14.  
    15. Remove the instrument panel-to-chassis screws and bolts.
    16.  
    17. Using an assistant, remove the instrument panel.
    18.  

  10.  
  11. If equipped with air conditioning, perform the following procedure:
    1. Discharge and recover the air conditioning refrigerant.
    2.  
    3. If equipped with a G16 or a J20 engine, disconnect the suction pipe and liquid pipe from the air conditioning housing. Plug the openings to prevent contamination.
    4.  
    5. If equipped with an H25 engine, disconnect the compressor suction pipe and receiver/drier outlet pipe from the air conditioning housing. Plug the openings to prevent contamination.
    6.  
    7. Remove the blower motor assembly.
    8.  
    9. Disconnect the thermistor wire coupler.
    10.  
    11. Remove the air conditioning housing.
    12.  

  12.  
  13. Disconnect the rear duct from the heater housing.
  14.  
  15. Disconnect the mode actuator electrical connectors.
  16.  
  17. If equipped, remove the air conditioning controller.
  18.  
  19. If equipped, disconnect and remove the Sensing and Diagnostic Module (SDM) or air bag controller module.
  20.  
  21. Remove the heater housing.
  22.  
  23. Remove the heater core pipe clamps and grommet.
  24.  
  25. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the instrument panel and fasteners-Suzuki Vitara



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing and ventilation ducts-Suzuki Vitara



    Click image to see an enlarged view

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

  26.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the heater core pipe clamps and grommet.
  4.  
  5. Install the heater housing.
  6.  
  7. If equipped, connect and install the Sensing and Diagnostic Module (SDM) or air bag controller module.
  8.  
  9. If equipped, install the air conditioning controller.
  10.  
  11. Connect the mode actuator electrical connectors.
  12.  
  13. Connect the rear duct from the heater housing.
  14.  
  15. If equipped with air conditioning, perform the following procedure:
    1. Install the air conditioning housing.
    2.  
    3. Connect the thermistor wire coupler.
    4.  
    5. Install the blower motor assembly.
    6.  
    7. If equipped with an H25 engine, connect the compressor suction pipe and receiver/drier outlet pipe to the air conditioning housing.
    8.  
    9. If equipped with a G16 or a J20 engine, connect the suction pipe and liquid pipe to the air conditioning housing.
    10.  
    11. Evacuate and charge the air conditioning system.
    12.  

  16.  
  17. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel.
    2.  
    3. Install the instrument panel-to-chassis screws and bolts.
    4.  
    5. Connect the instrument panel electrical connectors.
    6.  
    7. Install the hood opener.
    8.  
    9. Connect the speedometer connector and the speedometer assembly.
    10.  
    11. Install the steering column.
    12.  
    13. Connect the electrical connector and cables to the heater housing and blower motor assembly.
    14.  
    15. Install the glove box and the column hole cover.
    16.  
    17. Install the console.
    18.  

  18.  
  19. Connect the heater hoses to the heater core.
  20.  
  21. Refill the cooling system.
  22.  
  23. To enable the air bag system, perform the following procedure:
    1. Push inward on the glove box while pushing the stopper located at both sides and connect the passenger-s side air bag module yellow connector and lock it.
    2.  
    3. Under the steering column, connect the contact coil/combination switch assembly-s yellow connector.
    4.  
    5. In the fuse box, install the AIR BAG fuse.
    6.  
    7. Turn the ignition switch ON and verify that the AIR BAG warning light flashes 7 times and turns OFF; if the system does not operate as described, perform the Air Bad Diagnostic System Check.
    8.  

  24.  
  25. Connect the negative battery cable.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

  1. Disconnect the negative battery cable.
  2.  
  3. To disable the air bag system, perform the following procedure:
    1. Position the front wheels so that they are pointing straight ahead.
    2.  
    3. Turn the ignition switch to the LOCK position.
    4.  
    5. In the fuse box, remove the AIR BAG fuse.
    6.  
    7. Under the steering column, locate the contact coil/combination switch assembly-s yellow connector; then, unlock and disconnect the connector.
    8.  
    9. Pull outward on the glove box while pushing the stopper located at both sides and locate the passenger-s side air bag module yellow connector; then, unlock and disconnect the connector.
      NOTE
      With the AIR BAG fuse removed and the ignition switch turned ON; the air bag warning light may be ON; this is normal operation and does not indicate an air bag malfunction.

    10.  

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater core.
  8.  
  9. Remove the instrument panel by performing the following procedure:
    1. Remove the console.
    2.  
    3. Remove the glove box and the column hole cover.
    4.  
    5. Disconnect the electrical connector and cables from the heater housing and blower motor assembly.
    6.  
    7. Remove the steering column.
    8.  
    9. Disconnect the speedometer connector and the speedometer assembly.
    10.  
    11. Remove the hood opener.
    12.  
    13. Disconnect the instrument panel electrical connectors.
    14.  
    15. Remove the instrument panel-to-chassis screws and bolts.
    16.  
    17. Using an assistant, remove the instrument panel.
    18.  

  10.  
  11. If equipped with air conditioning, perform the following procedure:
    1. Discharge and recover the air conditioning refrigerant.
    2.  
    3. If equipped with a G16 or a J20 engine, disconnect the suction pipe and liquid pipe from the air conditioning housing. Plug the openings to prevent contamination.
    4.  
    5. If equipped with an H25 engine, disconnect the compressor suction pipe and receiver/drier outlet pipe from the air conditioning housing. Plug the openings to prevent contamination.
    6.  
    7. Remove the blower motor assembly.
    8.  
    9. Disconnect the thermistor wire coupler.
    10.  
    11. Remove the air conditioning housing.
    12.  

  12.  
  13. Disconnect the rear duct from the heater housing.
  14.  
  15. Disconnect the mode actuator electrical connectors.
  16.  
  17. If equipped, remove the air conditioning controller.
  18.  
  19. If equipped, disconnect and remove the Sensing and Diagnostic Module (SDM) or air bag controller module.
  20.  
  21. Remove the heater housing.
  22.  
  23. Remove the heater core pipe clamps and grommet.
  24.  
  25. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. View of the instrument panel and fasteners-Suzuki Vitara



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing and ventilation ducts-Suzuki Vitara



    Click image to see an enlarged view

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

  26.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the heater core pipe clamps and grommet.
  4.  
  5. Install the heater housing.
  6.  
  7. If equipped, connect and install the Sensing and Diagnostic Module (SDM) or air bag controller module.
  8.  
  9. If equipped, install the air conditioning controller.
  10.  
  11. Connect the mode actuator electrical connectors.
  12.  
  13. Connect the rear duct from the heater housing.
  14.  
  15. If equipped with air conditioning, perform the following procedure:
    1. Install the air conditioning housing.
    2.  
    3. Connect the thermistor wire coupler.
    4.  
    5. Install the blower motor assembly.
    6.  
    7. If equipped with an H25 engine, connect the compressor suction pipe and receiver/drier outlet pipe to the air conditioning housing.
    8.  
    9. If equipped with a G16 or a J20 engine, connect the suction pipe and liquid pipe to the air conditioning housing.
    10.  
    11. Evacuate and charge the air conditioning system.
    12.  

  16.  
  17. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel.
    2.  
    3. Install the instrument panel-to-chassis screws and bolts.
    4.  
    5. Connect the instrument panel electrical connectors.
    6.  
    7. Install the hood opener.
    8.  
    9. Connect the speedometer connector and the speedometer assembly.
    10.  
    11. Install the steering column.
    12.  
    13. Connect the electrical connector and cables to the heater housing and blower motor assembly.
    14.  
    15. Install the glove box and the column hole cover.
    16.  
    17. Install the console.
    18.  

  18.  
  19. Connect the heater hoses to the heater core.
  20.  
  21. Refill the cooling system.
  22.  
  23. To enable the air bag system, perform the following procedure:
    1. Push inward on the glove box while pushing the stopper located at both sides and connect the passenger-s side air bag module yellow connector and lock it.
    2.  
    3. Under the steering column, connect the contact coil/combination switch assembly-s yellow connector.
    4.  
    5. In the fuse box, install the AIR BAG fuse.
    6.  
    7. Turn the ignition switch ON and verify that the AIR BAG warning light flashes 7 times and turns OFF; if the system does not operate as described, perform the Air Bad Diagnostic System Check.
    8.  

  24.  
  25. Connect the negative battery cable.
  26.  
  27. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  28.  

 
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