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Home >> Suzuki >> 2008 >> XL7 Base, AWD >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating, Ventilation And A/C >> Repair Instructions >> HVAC Module Assembly Replacement >> Special Tools >> Removal Procedure
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Removal Procedure

  1. Disable the Supplemental Inflatable Restraints (SIR) system. Refer to SIR DISABLING AND ENABLING .
  2. Recover the refrigerant. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  3. Drain the engine coolant. Refer to COOLING SYSTEM DRAINING AND FILLING (LY7 GE 47716 FILL) or COOLING SYSTEM DRAINING AND FILLING (LY7 STATIC FILL) .
    Fig 1: Identifying Evaporator Outlet Hose And Liquid Line Nut
    G05470506Courtesy of SUZUKI OF AMERICA CORP.
  4. Remove the evaporator outlet hose and liquid line nut from the thermal expansion valve (TXV).
  5. Remove the evaporator outlet hose from the TXV.
  6. Remove and discard the sealing washer from the evaporator outlet hose. Refer to SEALING WASHER REPLACEMENT .
  7. Remove the evaporator outlet hose and liquid line from the TXV.
  8. Remove and discard the sealing washer from the liquid line. Refer to SEALING WASHER REPLACEMENT .
  9. Install a protective caps to the evaporator outlet hose and the liquid line to prevent contamination and desiccant saturation.
    Fig 2: Identifying Heater Outlet Hose
    G05470507Courtesy of SUZUKI OF AMERICA CORP.
  10. Reposition the heater outlet hose clamp at the heater core.
  11. Remove the heater outlet hose from the heater core.
  12. Reposition the heater inlet hose clamp at the heater core.
  13. Remove the heater inlet hose at the heater core.
  14. Plug the heater core and the evaporator core with clean towels to prevent spillage when the HVAC module is removed.
    Fig 3: Identifying HVAC Module Seal Nuts
    G05470508Courtesy of SUZUKI OF AMERICA CORP.
  15. Remove the HVAC module seal nuts from the front of dash.
  16. Remove the instrument panel (I/P) retainer. Refer to INSTRUMENT PANEL RETAINER REPLACEMENT .
  17. Remove the shift control bracket. Refer to TRANSMISSION CONTROL REPLACEMENT for the AF33-5 transaxle.
    Fig 4: Identifying Center Floor Air Outlet Duct
    G05470509Courtesy of SUZUKI OF AMERICA CORP.
  18. Remove the center floor air outlet duct by sliding the duct forward then up at the rear.
    Fig 5: Identifying Center I/P Air Outlet Duct
    G05470510Courtesy of SUZUKI OF AMERICA CORP.
  19. Remove the center I/P air outlet duct retainers from the instrument panel tie bar.
  20. Remove the center I/P air outlet duct from the instrument panel tie bar.
  21. Remove the instrument panel tie bar. Refer to INSTRUMENT PANEL TIE BAR REPLACEMENT .
  22. Disconnect the blower motor electrical connector from the I/P wire harness.
  23. Disconnect the blower motor control module electrical connector from the I/P wire harness.
  24. Disconnect the HVAC module electrical connector from the I/P wire harness.
    Fig 6: Identifying Defroster Duct
    G05470511Courtesy of SUZUKI OF AMERICA CORP.
  25. Remove the defroster duct retainer from the instrument panel tie bar.
  26. Remove the defroster duct from the HVAC module.
  27. Disconnect the I/P wire harness clips from the HVAC module.
    Fig 7: Identifying HVAC Module
    G05470512Courtesy of SUZUKI OF AMERICA CORP.
  28. Remove the HVAC module from the vehicle.
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