Water On The Passenger Floor When Using The Air Conditioner (TS 02 04018)

WATER ON THE PASSENGER FLOOR WHEN USING THE AIR CONDITIONER

TECHNICAL SERVICE BULLETIN

CONDITION

When using the air conditioning, water from the evaporator may drain inside the vehicle from the heater ducts, especially on turns.

CAUSE

Evaporator drain plugged with debris.

CORRECTION

The evaporator drain, blower fan, and cowl plenum require debris removal. To prevent future problems, install the 08MY filter and cowl plenum screen. See below for evaporator drain, blower fan clean out, and cowl plenum installation procedure.

PART(S) INFORMATION

Part Numbers	Description	QTY	Notes
95860-80J00	Filter	1	Part number comments may show 2008 MY in parts catalog, please disregard model year.
95861-80J00	Filter Cover	-1	Remove and discard.
95481-80J10	Drain Hose	0	For reference only
72451-80J10	Cowl Vent Center Cover	1
72460-80J10	Cowl Vent Side Cover	1

WARRANTY CLAIM INFORMATION

Labor Operation	Description	Failed Part Number	Complaint Code	Defect Code	Labor Time
TB9999	Drain Hose	95481-80J10	85	41	1.0 Hrs.

Evaporator Drain and Blower Cleaning

1. Raise the vehicle on a suitable lift.
2. Locate the evaporator drain hose under the vehicle.
   Fig 1: Locating Evaporator Drain Hose

   Courtesy of SUZUKI OF AMERICA CORP.
3. Using a wet/dry shop vacuum, apply suction to the drain hose in order to dislodge any obstruction as well as remove trapped water.
   Fig 2: Applying Suction To Drain Hose

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4. To apply maximum suction to the drain hose use an appropriate attachment or cover the hose with your finger enough to increase the suction to the drain line.
Fig 3: Identifying Hose Location
Courtesy of SUZUKI OF AMERICA CORP.
5. Apply the suction for a minute or two to drain the water and produce maximum drain line flushing.
6. Remove vehicle from lift.
7. Remove both front wiper blades. Make sure to mark the position of the shaft to aid in the re-installation.
   Fig 4: View Of Front Wiper Shaft

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8. Remove the rubber seal from the top cowl garnish. Vacuum any debris found on top of the cowl top garnish.
   Fig 5: Removing Rubber Seal From Top Cowl Garnish

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9. Disengage and remove the 7 indicated locking clips. Remove the right and left side cowl top garnish.
   Fig 6: Identifying Locking Clips

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   Fig 7: Removing Cowl Top Garnish

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10. Carefully lift the garnish up from the left side first and twist the front side of the garnish up. There are snap clips under the cowl cover which have to be released.
    CAUTION: The garnish has hooks which grip the underside of the windshield glass. It is possible to crack the glass if the garnish is removed harshly.
    Fig 8: Releasing Snap Hooks

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11. The rubber seal on the right and left edge of the cowl garnish will need to be removed for the garnish cover to clear the hood hinge.
    Fig 9: Clearing Hood Hinge

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12. Clean out any debris found inside the cowl vent area between the cabin and engine compartment.
    Fig 10: Identifying Cowl Vent Cleaning Area

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13. Install the cowl vent cover at the center position and right position.
    Fig 11: Identifying Cowl Vent Cover Installation Positions

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14. Slide the rear side of the vent cover onto the existing stud.
15. Remove the existing nut and mount the front side of the vent cover with the removed nut.
    Fig 12: Identifying Front Side Of Vent Cover Existing Stud

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    Fig 13: Identifying Front Side Of Vent Cover Existing Nut

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16. Installation of the center vent cover is similar.
    Fig 14: Identifying Center Vent Cover Existing Stud

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    Fig 15: Identifying Center Vent Cover Existing Nut

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17. Re-install the cowl top garnish and wiper arms. Torque wiper arm nut to 18 Nm (13 lb-ft).
18. Release the glove box damper and lower the glove box.
    Fig 16: Locating Glove Box Damper

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19. Remove the glove box by squeezing the sides to allow the limiting bumper to pass through the opening. Then lower enough to allow the hinge to release and set the glove box aside.
    Fig 17: Squeezing Glove Box

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    Fig 18: Releasing Glove Box

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20. Remove the filter cover from the blower case. Squeeze the tabs together on both sides and slide the cover straight out.
    Fig 19: Squeezing Tabs

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    Fig 20: Removing Filter Cover From Blower Case

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21. Disconnect the electrical connector at the back side of the motor. The lock release is on the driver side of the connector as plugged into the motor.
    Fig 21: View Of Electrical Connector At Back Side Of Motor

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22. Remove the blower motor by removing the two screws.
23. Pull the tab down then rotate the motor clockwise to release it from the housing.
    Fig 22: Removing Blower Motor

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    Fig 23: Identifying Blower Motor

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24. Use the wet/dry vacuum to remove as much debris as possible from inside the HVAC unit by placing the suction hose into the blower outlet as indicated.
    Fig 24: Placing Suction Hose Into Blower Outlet

    Courtesy of SUZUKI OF AMERICA CORP.
25. Install the new filter (95860-80J00) in the location where the filter cover or used filter was removed in step 20.
26. Re-install the blower motor and glove box.