Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSUZUKI2005VERONA L6-2.5LREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCONTROL MODULE HVACSERVICE AND REPAIR
2005 Suzuki Verona L6-2.5L
Control Module HVAC: Service and Repair
2005 Suzuki Verona L6-2.5LSECTION Service and Repair
A/C Module Removal and Installation
A/C Module Removal
1. Disconnect the negative battery cable.
2. Remove the instrument panel carrier assembly. Refer to Instrument Panel Removal.
3. Drain the cooling system. Refer to Draining and Refilling the Cooling System.
4. Recover the refrigerant. Refer to Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System
5. Remove the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.
6. Loosen the clamp bolts from the suction hose and the liquid evaporator pipe to allow movement of the hose and the pipe.
7. Remove the evaporator drain hose.
8. Compress the heater hose clamps at the fire wall and slide the clamps toward the engine.
9. Remove the two heater hoses from the core lines at the fire wall.
10. Remove the screws that secure the A/C module to the fire wall on either side of the heater hoses.
11. Remove the A/C module screw, that is located above the fuel filter, from the engine compartment side of the fire wall.
12. Have an assistant support the A/C module from inside the vehicle.
13. Remove the A/C module screws from the evaporator flange on the engine compartment side of the fire wall. The A/C module will start to drop.
14. Pull the case straight away from the fire wall.
15. Remove the A/C module from the vehicle.
A/C Module Installation
1. Position the A/C module in the vehicle.
CAUTION: To avoid damaging the heater core tubes, make sure they do not contact the fire wall opening.
2. Slowly raise the A/C module into position and hold it against the fire wall while the screws are installed and tightened from the engine side of the fire wall.
3. Align and install the A/C module screws above the fuel filter and at the evaporator flange.
Tighten:
Tighten the A/C module screws to 8 N.m (71 lb.in).
4. Install the A/C module screws adjacent to the heater hoses.
Tighten:
Tighten the A/C module screws to 8 N.m (71 lb.in).
5. Install the evaporator drain hose.
6. Install the two heater hoses.
7. Slide the heater hose clamps into position.
8. Install the instrument panel carrier assembly. Refer to Instrument Panel Installation.
9. Install new O-rings on the suction hose and the liquid evaporator pipe at the fire wall and put the pipes back in place.
10. Install the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.
Tighten:
Tighten the suction hose and the liquid evaporator pipe retaining nuts to 10 N.m (89 lb.in).
11. Fill the cooling system. Refer to Draining and Refilling the Cooling System.
12. Recharge the A/C system. Refer to Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System.
13. Connect the negative battery cable.
A/C Module Removal
1. Disconnect the negative battery cable.
2. Remove the instrument panel carrier assembly. Refer to Instrument Panel Removal.
3. Drain the cooling system. Refer to Draining and Refilling the Cooling System.
4. Recover the refrigerant. Refer to Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System
5. Remove the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.
6. Loosen the clamp bolts from the suction hose and the liquid evaporator pipe to allow movement of the hose and the pipe.
7. Remove the evaporator drain hose.
8. Compress the heater hose clamps at the fire wall and slide the clamps toward the engine.
9. Remove the two heater hoses from the core lines at the fire wall.
10. Remove the screws that secure the A/C module to the fire wall on either side of the heater hoses.
11. Remove the A/C module screw, that is located above the fuel filter, from the engine compartment side of the fire wall.
12. Have an assistant support the A/C module from inside the vehicle.
13. Remove the A/C module screws from the evaporator flange on the engine compartment side of the fire wall. The A/C module will start to drop.
14. Pull the case straight away from the fire wall.
15. Remove the A/C module from the vehicle.
A/C Module Installation
1. Position the A/C module in the vehicle.
CAUTION: To avoid damaging the heater core tubes, make sure they do not contact the fire wall opening.
2. Slowly raise the A/C module into position and hold it against the fire wall while the screws are installed and tightened from the engine side of the fire wall.
3. Align and install the A/C module screws above the fuel filter and at the evaporator flange.
Tighten:
Tighten the A/C module screws to 8 N.m (71 lb.in).
4. Install the A/C module screws adjacent to the heater hoses.
Tighten:
Tighten the A/C module screws to 8 N.m (71 lb.in).
5. Install the evaporator drain hose.
6. Install the two heater hoses.
7. Slide the heater hose clamps into position.
8. Install the instrument panel carrier assembly. Refer to Instrument Panel Installation.
9. Install new O-rings on the suction hose and the liquid evaporator pipe at the fire wall and put the pipes back in place.
10. Install the retaining nuts that secure the suction hose and the liquid evaporator pipe blocks at the fire wall.
Tighten:
Tighten the suction hose and the liquid evaporator pipe retaining nuts to 10 N.m (89 lb.in).
11. Fill the cooling system. Refer to Draining and Refilling the Cooling System.
12. Recharge the A/C system. Refer to Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System.
13. Connect the negative battery cable.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.