Get Heater (Optional) and Ventilation Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

HEATER AND VENTILATION 1A-1

SECTION 1A

HEATER (OPTIONAL) AND VENTILATION

NOTE:

The link mechanism of the heater varies depending on the specifications.

CONTENTS

GENERAL DESCRIPTION 1A- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis Table 1A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Circuit 1A- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON VEHICLE SERVICE 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Unit 1A- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Fan Motor 1A- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Fan Motor Resistor 1A- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heater Control Lever Assembly 1A- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Fan Motor Switch 1A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Inlet Box 1A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A-2 HEATER AND VENTILATION

GENERAL DESCRIPTION

The heater and ventilation consist of the following parts.

1. Heater unit

2. Air inlet box or cooling unit

3. Ventilator duct

4. Defroster nozzle

5. Ventilation louver

6. Ventilation air

7. Foot air

8. Defroster air

9. Demister air

10. Fresh air

11. Recirculation air

12. Engine

13. Water valve

HEATER AND VENTILATION 1A-3

DIAGNOSIS

DIAGNOSIS TABLE

Trouble

Possible Cause Remedy

Heater blower fan motor won’t

work even when its switch is

operating position.

Fuse blown

Blower fan motor resistor faulty

Blower fan motor switch faulty

Blower fan motor faulty

Wiring or grounding faulty

Check “HTR” fuse, and check for

short circuit to ground.

Check resistor.

Check blower fan switch.

Replace motor.

Repair as necessary.

Incorrect temperature output. Control cables broken or binding

Temperature control lever faulty

Position of control cable clamp is faulty

Air damper broken

Air ducts clogged

Water valve faulty

Heater core leaking or clogged

Heater hoses leaking or clogged

Thermostat faulty

Check cables.

Check control lever.

Check and adjust clamp position.

Repair damper.

Repair air ducts.

Replace water valve.

Replace core.

Replace hoses.

Check thermostat.

When mode control lever is

changed, air outlet port is not

changed or lever position

disagree with air outlet port.

Control cables broken or binding

Mode control lever faulty

Position of control cable clamp is faulty

Air damper broken

Air ducts leaking or clogged

Check cable.

Check control lever.

Check and adjust clamp position.

Repair damper.

Repair air ducts.

1. Blower fan motor

2. Blower fan motor resistor

3. Blower fan motor switch

4. Ignition switch

5. To A/C switch (if equipped)

6. To ECM (Idle up signal)

1A-4 HEATER AND VENTILATION

WIRING CIRCUIT

ON VEHICLE SERVICE

HEATER UNIT

1. Heater core

2. Blower fan motor assembly

3. Blower fan motor resistor

4. Temperature door assembly

5. Air outlet control door assembly

6. Air outlet control lever

7. Temperature control lever

8. Heater case

9. Water valve

HEATER AND VENTILATION 1A-5

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Drain engine coolant and disconnect heater hoses (1) from

heater unit.

3) Remove instrument panel.

4) Disconnect each couplers (blower motor, resistor) from heater

unit.

5) Remove bolts (2), nuts (3) and screws (4) (if vehicle equipped

with A/C) as shown.

6) Remove heater unit (5) from vehicle.

INSTALLATION

Install heater unit by reversing removal procedure, noting the fol-

lowing items.

D When installing each part, be careful not to catch any cable or

wiring harness.

D Adjust heater control cable (refer to heater control lever assem-

bly in this section).

D Fill engine coolant to radiator, refer to ENGINE COOLANT

CHARGE in Section 0B.

1A-6 HEATER AND VENTILATION

BLOWER FAN MOTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disconnect blower motor coupler.

3) Loosen water valve by removing its attaching screws (1).

4) Remove blower fan motor (2) by removing it attaching screws

(3).

INSPECTION

Check continuity between two terminal as shown in figure.

If check results are continuity, proceed to next operation check, if

not replace.

Connect battery to blower fan motor as shown, then check that the

blower motor (1) operates smoothly.

INSTALLATION

Reverse removal procedure for installation.

HEATER AND VENTILATION 1A-7

BLOWER FAN MOTOR RESISTOR

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disconnect resistor coupler (1).

3) Remove blower motor resistor (2) by removing its mounting

screw (3).

INSPECTION

Measure each terminal-to-terminal resistance on resistor

Resistance Me – Lo: 1.5 – 3.0 W at 255C (775F)

Me – Hi : 0.5 – 1.5 W at 255C (775F)

If measured resistance is incorrect, replace blower motor resistor.

INSTALLATION

Reverse removal procedure for installation.

1A-8 HEATER AND VENTILATION

HEATER CONTROL LEVER ASSEMBLY

1. Heater control lever assembly

2. Bulb

3. Fresh air control cable

4. Air outlet control cable

5. Temperature control cable

6. Temperature control knob

7. Air outlet control knob

8. Fresh air control knob

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disconnect each heater control cables (air outlet control (1),

temperature control (2) and fresh air control) from heater unit

and air inlet box or cooling unit (if equipped with A/C).

3) Disconnect heater control panel illumination coupler and A/C

switch coupler (if equipped).

4) Loosen steering column assembly, refer to “STEERING COL-

UMN” in section 3C.

5) Remove temperature control knob (1), air outlet control knob (2)

and blower fan motor switch knob (3).

6) Remove meter cluster (4) by removing its mounting screws.

HEATER AND VENTILATION 1A-9

7) Remove heater control lever assembly (1) by removing mount-

ing screws.

INSTALLATION

1) Reverse removal procedure for installation.

2) Adjust the following items.

i) Move air outlet control knob (a), temperature control knob (b)

and fresh air control knob (c) fully in arrow direction as shown

in figure.

ii) Push air outlet lever (d), temperature lever (e) and door link

(f) fully in arrow direction and fix cable with clamp in position

as shown in figure.

NOTE :

After installing control cables, be sure that control levers

move smoothly and stop at proper position.

1. Heater unit

2. Air inlet box or cooling unit

3. Air outlet control cable

4. Temperature control cable

5. Fresh air control cable

1A-10 HEATER AND VENTILATION

BLOWER FAN MOTOR SWITCH

REMOVAL

1) Disconnect negative (–) cable at battery.

2) Disconnect heater control panel illumination coupler and A/C

switch coupler (if equipped).

3) Loosen steering column assembly, refer to STEERING COL-

UMN in section 3C.

4) Remove temperature control knob (1), air outlet control knob (2)

and blower fan motor switch knob (3).

5) Remove meter cluster (4) by removing its mounting screws (5).

6) Disconnect blower fan switch coupler.

7) Loosen blower fan switch screw (1) and then remove blower fan

motor switch (2) from instrument panel.

INSPECTION

Check blower fan switch for each terminal-to-terminal continuity.

For the detail refer to “WIRING CIRCUIT” earlier in this section.

POSITION

TERMINAL

INSTALLATION

Reverse removal sequence to install blower fan switch.

HEATER AND VENTILATION 1A-11

E L M H

OFF

AIR INLET BOX

REMOVAL

NOTE:

If vehicle is equipped with air conditioning, refer to COOLING

UNIT in Section 1B.

1) Remove fresh air control cable (1) from air inlet box (2).

2) Open glove box lid (4).

3) Loosen air inlet box mounting nut (1) and screws (2).

4) Remove air inlet box (3).

INSTALLATION

NOTE:

If vehicle is equipped with air conditioning, refer to COOLING

UNIT in Section 1B.

Reverse removal sequence to install air inlet box, noting the follow-

ing point.

D Adjust fresh air control cable, refer to HEATER CONTROL LE-

VER ASSEMBLY in this section.

1A-12 HEATER AND VENTILATION

Heater (Optional) and Ventilation for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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