blower SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

YH4
GRAND
VITARA
1A
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either or these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
The link mechanism of the heater varies depending on the specifications.
CONTENTS
GENERAL DESCRIPTION1A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Ventilation1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Circuit1A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Unit1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor1A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Relay1A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Resistor1A- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Switch1A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Actuator1A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Lever Assembly 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Cables1A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit1A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Duct1A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Side ventilator outlet
2. Side defroster outlet
3. Center ventilator outlet
4. Heater unit
5. Defroster duct6. Ventilator duct
7. Heater control lever assembly
8. Heater mode control switch
9. Blower unit
10. Rear duct
1A-2 HEATER AND VENTILATION
GENERAL DESCRIPTION
The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an
agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left)
of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets
at places, right and left, along the windshield glass.
The heater and ventilation consist of following parts.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

YH4
GRAND
VITARA
1A-4 HEATER AND VENTILATION
FOR LH VEHICLE
FOR RH VEHICLE
1. From ignition switch 1
2. From ignition switch 2
3. From blower fuse
4. Head light relay
5. To A / C controller6. Blower motor relay
7. Blower motor switch
8. Blower resistor
9. Blower motor
10. To ECM11. To illumination controller
(if equipped) or body ground
12. Mode control actuator
13. Mode control switch
14. From main fuse15. TAIL fuse 15 A
16. IG METER fuse 20 A
17. HEATER fuse 30 A
18. REAR DEFG fuse 15 A
19. Drive circuit
WIRING CIRCUIT

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-5
1. Blower unit
2. Blower motor resistor
3. Blower motor relay
4. Blower fan
5. Blower motor
3. Cover
ON-VEHICLE SERVICE
BLOWER UNIT
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Remove passenger lower member (1).
4) Remove ECM (1) with bracket (2) from blower motor unit (4).
5) Disconnect blower motor (1), blower motor relay (2) and resistor
lead wires (3) at couplers.

YH4
GRAND
VITARA
1A-6 HEATER AND VENTILATION
6) Remove cooling unit (If equipped).
Refer to item COOLING UNIT (EVAPORATOR) REMOVAL in
Section 1B.
7) Disconnect fresh air control cable from blower motor case.
8) Remove blower motor unit (1) by removing its fastening nuts
(2).
9) Disconnect blower motor lead wire (2) at coupler from blower
unit (1).
10) Remove blower motor (3) by removing its mounting screws (4).
INSTALLATION
1) Reverse removal procedure for installation.
2) Connect fresh air control cable, refer to HEATER CONTROL
CABLES INSTALLATION.
3) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-7
1. Fastening nuts
1. Air flow
BLOWER MOTOR
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Remove ECM with bracket from blower motor unit.
4) Disconnect harness clamps from dash panel.
5) Loosen three nuts fastening blower unit.
6) Disconnect blower motor lead wire at coupler (2).
7) Remove blower motor (3) from blower unit (1).
INSPECTION

Check continuity between terminal to terminal as shown in left fig-
ure.
If check results are continuity, proceed to next operation check.
If not, replace.

Connect battery to blower motor as shown, then check that the
blower motor operates smoothly and specified current.
Specified current: Max. 25 A at 12 V
INSTALLATION
1) Reverse removal procedure for installation.
2) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
1A-8 HEATER AND VENTILATION
BLOWER MOTOR RELAY
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Open glove box, then remove screw.
4) Remove glove box.
5) Disconnect relay coupler.
6) Remove blower motor relay (1) by removing its fastening screw (2).
INSPECTION
1) Check that there is no continuity between terminal ªcº and ªdº.
If there is continuity, replace relay.
2) Connect battery positive (+) terminal to terminal ªbº of relay.
Connect battery negative (±) terminal ªaº of relay.
Check continuity between terminal ªcº and ªdº.
If there is no continuity when relay is connected to the battery,
replace relay.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-9
1. LO
2. M1
3. M2
4. HI
BLOWER MOTOR RESISTOR
REMOVAL
1) Disconnect negative (±) cable (2) at battery (1).
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Open glove box (1), then remove screw (2).
4) Remove glove box.
5) Disconnect blower motor resistor (1) at coupler.
6) Remove heater blower resistor (1) by removing its fastening
screw (2).
INSPECTION
Measure each terminal-to-terminal resistance on resistor.
Resistance H-LO: Approx. 2.0

H-M1: Approx. 1.0

H-M2: Approx. 0.4

If measured resistance is incorrect, replace heater blower resistor.
INSTALLATION
1) Install heater blower resistor with screws.
2) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
1A-10 HEATER AND VENTILATION
2. Screws1 2
HEATER MODE CONTROL SWITCH
REMOVAL
1) Disconnect negative (±) cable at battery.
2) If equipped with air bag system, disable air bag system.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.
3) Remove meter cluster hood (1) by removing its mounting
screws (2).
4) Remove ashtray, center garnish (1) and instrument glove box
compartment.
5) Remove radio (1) (if equipped) or clock or accessory case.
6) Disconnect control cables (3) from blower motor unit (2) and
heater unit (1).