Suzuki Grand Vitara JB419. Manual - part 123

Heater and Ventilation:  7A-4

Repair Instructions

Heater Core Removal and Installation

S5JB0B7106010

Removal

1) Remove instrument panel referring to “Instrument 

Panel Removal and Installation in Section 9C in 
related manual”.

2) Remove HVAC unit. Refer to “HVAC Unit Removal 

and Installation in Section 7B”.

3) Remove heater core pipe clamp and then, pull out 

heater core (1) from HVAC unit.

Installation

1) Install heater core by reversing removal procedure, 

noting the following items.
• When installing heater core, be careful not to 

damage fins of heater core.

• When installing each part, be careful not to catch 

any wiring harness.

2) Fill engine coolant referring to step 13) to 20) of 

“Cooling System Refilling in Section 1F”.

3) Enable air bag system referring to “Enabling Air Bag 

System in Section 8B in related manual”.

Additional Heater Relay Inspection

S5JB0B7106024

1) Disconnect negative (–) cable at battery.
2) Remove additional heater relay No.1 (1), No.2 (2) 

and No.3 (3) from vehicle.

3) Check that there is no continuity between terminal 

“c” and “d”. If there is continuity, replace relay.

4) Connect battery positive (+) terminal to terminal “b” 

of relay and battery negative (–) terminal to terminal 
“a” of relay.
Check that there is continuity between terminal “c” 
and “d”.If there is no continuity, replace relay.

Heating performance is 
poor (for additional heater 
system)

Fuse blown

Check related fuses and check for short circuit 
to ground.

Additional heater relays faulty

Check additional heater relays referring to 
“Additional Heater Relay Inspection”.

Additional heater assembly faulty

Check additional heater assembly referring to 
“Additional Heater Assembly On-Vehicle 
Inspection”.

ECM faulty

Check ECM.

Wiring or grounding faulty

Repair as necessary.

Condition

Possible cause

Correction / Reference Item

1

I6JB01710006-01

a

b

c

d

1

2

3

I5JB0B710005-01

7A-5 Heater and Ventilation: 

Additional Heater Assembly On-Vehicle 
Inspection

S5JB0B7106025

1) Disconnect negative (–) cable at battery.
2) Disconnect wires from additional heater terminals.

NOTE
Make alignment marks (1) on wires and 
additional heater body for a guide during 
reinstallation, if necessary.

 

3) Check resistance between each terminal of 

additional heater and vehicle body ground. If 
resistance is out of specification, replace additional 
heater assembly with new one.

Additional heater terminal resistance
0.55 – 0.65 

Ω at 20 °C (68 °F)

Additional Heater Assembly Removal and 
Installation

S5JB0B7106026

Removal

1) Disconnect negative (–) cable at battery.
2) Drain engine coolant referring to “Cooling System 

Draining in Section 1F”.

3) Remove intercooler outlet pipe referring to 

“Intercooler and Air Intake Pipe Components in 
Section 1D”.

4) Disconnect additional heater wires (1) and heater 

hoses (2) from additional heater assembly (3).

NOTE
Make alignment marks on wires and 
additional heater body for a guide during 
reinstallation, if necessary.

 

5) Remove additional heater assembly (3) from its 

bracket.

Installation
Reverse the removal procedure for installation noting the 
followings.
• Tighten additional heater wire nuts to specified torque.

Tightening torque
Additional heater wire nut (a):  4 N·m (0.4 kgf-m, 
3.0 lb-ft)

• Fill engine coolant referring to step 13) to 20) of 

“Cooling System Refilling in Section 1F”. 

1

1

I5JB0B710006-01

I5JB0B710007-02

2

3

2

1

I5JB0B710008-01

(a)

I5JB0B710009-01

Heater and Ventilation:  7A-6

Specifications

Tightening Torque Specifications

S5JB0B7107001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Additional heater wire nut

4

0.4 

3.0

)

7B-1 Air Conditioning System: 

HVAC

Air Conditioning System

Precautions

Precautions on Servicing Refrigerant Line

S5JB0B7200005

• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts 

and O-ring.

• Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.
• Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install 

a blind plug or cap to the fitting immediately.

• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• Tighten bolts to specified torque.

Tightening torque
Refrigerant line bolt:  12 N·m (1.2 kgf-m, 9.0 lb-ft)

• Route drain hose so that drained water does not make any contact to vehicle components.

[A]

[B]

4

1

2

3

5

1

4

3

5

2

I5JB0B720021-04

[A]: LH steering vehicle

2. Discharge hose

5. Pressure sensor

[B]: RH steering vehicle

3. Liquid pipe

: Apply compressor oil (refrigerant oil) to O-ring.

1. Suction hose

4. Expansion valve