Suzuki Grand Vitara JB416 / JB420. Manual - part 294

7B-67 Air Conditioning System: 

HVAC Unit Components

S5JB0A7206011

20

19

21

25

16

17

22

22

18

3

2

1

5

23

24

16

15

26

26

26

27

26

4

6

14

1

7

9

13

12

10

8

11

I6JB01720012-01

1. Blower upper case

10. Blower lower case

19. Temperature control links

2. Air intake control actuator

11. Blower motor

20. Temperature control actuator

3. Air intake control links

12. Blower motor controller

21. Inside air temperature sensor

4. Air filter (if equipped)

13. Foot duct

22. Air flow control links

5. Air filter cover

14. Aspirator

23. Air flow control links cover

6. Air intake control door assembly

15. Heater core

24. Air flow control actuator

7. Expansion valve

16. Heater unit upper case

25. Aspirator hose

8. Evaporator

17. Temperature control door assembly

26. Packing

9. Evaporator temperature sensor

18. Air flow control door assembly

27. O-ring

Air Conditioning System:  7B-68

CAUTION

!

 

Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat 
head screwdriver or pair of pliers.

 

HVAC Unit Removal and Installation

S5JB0A7206012

Removal

WARNING

!

 

Failure to follow the following procedure and 
WARNING may cause air bag deployment, 
personal injury, damage to parts, or air bag 
being unable to deploy.
• Never rest a steering column assembly on 

steering wheel with air bag (inflator) 
module face down and column vertical.

• When handling the air bag (inflator) 

modules (driver and passenger), be careful 
not to drop it or apply an impact to it. If an 
excessive impact was applied (e.g., 
dropped from a height of 91.4 cm (3 feet) or 
more, never attempt disassembly or repair 
but replace it with a new one.

• When grease, cleaning agent. Oil, water, 

etc. has got onto air bag (inflator) modules 
(driver and passenger), wipe off 
immediately with a dry cloth.

 

1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air 

Bag System in Section 8B”.

3) Recover refrigerant from A/C system using recovery 

and recycling equipment referring to “Recovery” in 
“Operation Procedure for Charging A/C with 
Refrigerant”.

4) Drain engine coolant and disconnect heater hoses 

(1) from HVAC unit.

5) Disconnect suction hose (2) and condenser outlet 

hose (3) by removing attaching bolt (4).

6) Remove instrument panel referring to “Instrument 

Panel Removal and Installation in Section 9C”.

7) Disconnect rear duct from HVAC unit.
8) Detach wiring, connectors and clamps from HVAC 

unit.

9) Remove HVAC unit (1).

Installation

1) Install HVAC unit by reversing removal procedure, 

noting the following items.
• When installing each part, be careful not to catch 

any wiring harness.

• Replenish specified amount of compressor oil to 

compressor suction side referring to “Precautions 
on Replenishing Compressor Oil”.

• Install the padding (1) to the installation hole 

uniformly.

• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air 

Bag System in Section 8B”.

• Evacuate and charge system. Refer to “Operation 

Procedure for Charging A/C with Refrigerant”.

1

3

2

4

I5JB0A720043-01

1

I5JB0A720044-01

7B-69 Air Conditioning System: 

A/C Evaporator Removal and Installation

S5JB0A7206013

Removal

1) Remove HVAC unit referring to “HVAC Unit Removal 

and Installation”.

2) Remove evaporator (1) from HVAC unit by 

disassembling HVAC unit.

3) Remove evaporator temperature sensor from 

evaporator.

Installation
Reverse removal procedure to install A/C evaporator 
nothing the following instructions.
• Install evaporator temperature sensor onto evaporator 

referring to “A/C Evaporator Temperature Sensor 
Removal and Installation”.

A/C Evaporator Inspection

S5JB0A7206014

1) Check evaporator fins for blockage. If found clogged, 

use compressed air to clean the fins.

CAUTION

!

 

• Do not use water for cleaning of 

evaporator.

• Be careful not to damage evaporator fins. 

If evaporator fin is bent, straighten it by 
using a screwdriver or pair of pliers. If any 
leakage is found from fitting or tube, repair 
or replace evaporator.

 

2) Check inlet and outlet fittings for crack or scratch. 

Repair them as required.

A/C Evaporator Temperature Sensor Removal 
and Installation

S5JB0A7206015

Removal

1) Remove A/C evaporator (1) referring to “A/C 

Evaporator Removal and Installation”.

2) Remove A/C evaporator temperature sensor (2) 

from evaporator.

Installation

1) Identify evaporator by the following tables.

NOTE
As for Evaporator, there are 4 varieties 
depending on the internal structure.

 

1

I5JB0A720045-02

Evaporator 

type

Selection condition

A

LH steering vehicle

Evaporator with 
protection rubber (1)

B

Evaporator without 
protection rubber (2)

C

RH steering vehicle

Evaporator with 
protection rubber

D

Evaporator without 
protection rubber

3. Protection rubber

1

2

I5JB0A720046-01

1

2

3

I5GEB4720001-01

Air Conditioning System:  7B-70

2) Install evaporator temperature sensor onto 

evaporator in a correct position as shown in figure.

CAUTION

!

 

Mis-position causes insufficiency cooling 
and damaged of A/C system.

 

A/C Evaporator Temperature Sensor Inspection

S5JB0A7206016

Check resistance between A/C evaporator temperature 
sensor terminals. If check result is not in specification, 
replace A/C evaporator temperature sensor with the new 
one.

A/C evaporator temperature sensor resistance
11.2 – 11.5 k

Ω at 0 °C (32 °F)

3.8 – 3.9 k

Ω at 25 °C (77 °F)

Expansion Valve On-Vehicle Inspection

S5JB0A7206018

Refer to “A/C System Performance Inspection”.

[A]: Evaporator type A 

5. Holding part fixed to fin of 6th 

line from the left-side edge

[B]: Evaporator type B

6. Sensor part fixed to fin of 5th 

line from the left-side edge

[C]: Evaporator type C

7. Holding part fixed to fin of 3rd 

line from the left-side edge

[D]: Evaporator type D

8. Sensor part fixed to fin of 8th 

line from the right-side edge

1. Evaporator temperature 

sensor

9. Holding part fixed to fin of 6th 

line from the right-side edge

2. Evaporator

10. Sensor part fixed to fin of 5th 

line from the right-side edge

3. 34.5 mm (1.36 in.)

11. Holding part fixed to fin of 3rd 

line from the right-side edge

4. Sensor part fixed to fin of 8th 

line from the left-side edge

4

2

5

6

7

9

8

11

10

3

[A]

[B]

2

3

2

3

[C]

[D]

2

3

1

1

1

1

I5GEB4720002-03

1. Expansion valve

(k

Ω

)

11.4

3.9
3.3

0

32

25
77

30
86

(˚C)

(˚F)

Resistance

Temperature

I5JB0A720090-03

IYSQ01720049-01