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Home >> Suzuki >> 2009 >> XL7 Limited, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 74 (Heating, Ventilation And A/C) >> Repair Instructions >> HVAC Module Assembly Replacement >> Special Tools >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2008 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying HVAC Module
G05470513Courtesy of SUZUKI OF AMERICA CORP.
NOTE: Make sure the HVAC module seals are flush and even as they meet their mating surfaces. This will reduce the chance of leaks and ensure proper fit.
  1. Inspect the front of dash seal for proper alignment.
  2. Inspect the seal mating surfaces to ensure there are no obstructions.
  3. Position the HVAC module in the vehicle.
  4. Install, but do not tighten, the seal nuts to the front of dash.
  5. Install the instrument panel tie bar. Refer to INSTRUMENT PANEL TIE BAR REPLACEMENT .
    Fig 2: Identifying HVAC Module Seal Nuts
    G05470514Courtesy of SUZUKI OF AMERICA CORP.
    CAUTION: Refer to FASTENER NOTICE .
    NOTE: New front of dash seal nuts must be used to prevent leaks.
  6. Tighten the HVAC module seal nuts to the front of dash. Draw the HVAC module to the front of dash evenly by alternating between the seal nuts.

    Tightening torque 

    Tighten the nuts to 9 N.m (80 lb in). 

    Fig 3: Identifying Defroster Duct
    G05470515Courtesy of SUZUKI OF AMERICA CORP.
  7. Install the defroster duct to the HVAC module.
  8. Install the defroster duct retainer to the instrument panel tie bar.
  9. Connect the I/P wire harness clips to the HVAC module.
  10. Connect the blower motor electrical connector to the I/P wire harness.
  11. Connect the blower motor control module electrical connector to the I/P wire harness.
  12. Connect the HVAC module electrical connector to the I/P wire harness.
    Fig 4: Identifying Center I/P Duct
    G05470516Courtesy of SUZUKI OF AMERICA CORP.
  13. Install the center I/P duct to the instrument panel tie bar.
  14. Install the center I/P duct retainers to the instrument panel tie bar.
    Fig 5: Identifying Center Floor Air Outlet
    G05470517Courtesy of SUZUKI OF AMERICA CORP.
  15. Install the center floor air outlet by sliding forward onto the front floor air outlet then down and rearward over the rear floor air outlet.
  16. Install the shift control bracket. Refer to TRANSMISSION CONTROL REPLACEMENT for the AF33-5 transaxle.
  17. Install the I/P retainer. Refer to INSTRUMENT PANEL RETAINER REPLACEMENT .
    Fig 6: Identifying Heater Outlet Hose
    G05470518Courtesy of SUZUKI OF AMERICA CORP.
  18. Install the heater inlet hose to the heater core.
  19. Install the heater inlet hose clamp to the heater core.
  20. Install the heater outlet hose to heater core outlet.
  21. Install the heater outlet hose clamp to the heater core.
    Fig 7: Identifying Evaporator Outlet Hose And Liquid Line Nut
    G05470519Courtesy of SUZUKI OF AMERICA CORP.
  22. Ensure the mating surfaces are clean and free of debris, and install new seal washers to the evaporator outlet hose and the liquid line. Refer to SEALING WASHER REPLACEMENT .
  23. Install the evaporator outlet hose and the liquid line to the TXV.
  24. Install the evaporator outlet hose and liquid line nut to the TXV.

    Tightening torque 

    Tighten the nut to 20 N.m (15 lb ft). 

  25. Enable the Supplemental Inflatable Restraints (SIR) system. Refer to SIR DISABLING AND ENABLING .
  26. Fill the coolant. Refer to COOLING SYSTEM DRAINING AND FILLING (LY7 GE 47716 FILL) or COOLING SYSTEM DRAINING AND FILLING (LY7 STATIC FILL) .
  27. Evacuate and charge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING .
  28. Test the affected A/C joints for leaks using J 39400-A.
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