86-95 Suzuki Samurai Heater Water Control Valve Wire Cable (SKU# SIB-HCVW) Installation Instructions CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Suggested Tools: Combination Wrench: 10 mm Small Standard Screwdriver #1 Phillips Screwdriver Socket: 10 mm Ratchet Permanent Marker
Temperature Control Valve Components Inner Cable Outer Cable Valve Bracket Adjustment Clamp (Open Position) Climate Control Assembly Control Valve Lever To Temperature Control Valve in the Engine Compartment. Temperature Control Lever Temperature Control Valve Cable Temperature Control Valve (Connected to the firewall inside the engine compartment)
Note of Explanation: The Samurai we used for these instructions was not equipped with a radio of stereo. Consequently, we used illustrations which we hope will guide you if you need to remove a radio. If you have an aftermarket stereo we recommend you refer to the manufacturer for removal instructions. Step 1 Disconnect the negative battery cable using a 10 mm box end wrench. Note: The vehicle we used had an aftermarket cable so we used a 1/2 wrench. Step 2 Remove the Radio. Note: If the vehicle you are working on is NOT equipped with a radio (or stereo), skip to Step #3. If the vehicle you are working on IS equipped with a radio, continue to the next step.
Step 2 Continued 1. Pull off the (4) knobs. (See Figure A) 2. Remove the (2) faceplate nuts using a deep socket. 3. Remove the face plate. 4. Remove the (2) retainer nuts using a deep socket. Figure A 5. Let the radio drop down and forward (toward the front of the vehicle) until you can access the console bolt. 6. Remove the console bolt. 7. Force the console unit rearward (away from the engine) unlocking it from the radio mount bracket. Mount Bracket Console Bolt Face Plate Radio Face Plate Nuts (2) Console Locks (4) Console Retainer Nuts (2) Knobs (4)
Step 3 Remove the radio bracket by removing the (2) bolts using a 10 mm socket. Step 4 Pull off the (4) heater control knobs. Step 5 Unsnap the left side of the faceplate by tugging gently with a small standard screwdriver or a suitable hook. Step 5 Continued Unsnap the right side of the face plate in the same way.
Step 6 Pull the faceplate forward and unplug the backlight. Then set the faceplate aside. Note: The backlight is removed by twisting 1/4 turn counter clockwise and pulling. Step 7 Remove the (2) climate control mounting screws using a phillips screwdriver. Step 8 From under the dash work the control panel forward (toward the engine) as far as you can. It should move about an inch. Note: Do not force the unit. Step 9 Disconnect the control valve cable from the cable clamp using a #1 phillips screwdriver. Just loosen the screw. Do NOT remove it. Note: To gain access to this screw you will need to extend the phillips screwdriver through a radio bracket bolt hole.
Step 10 Once the screw is loose enough, slip the cable out of the bracket. Step 11 Flex the cable downward and unhook the inner cable from the lever as shown. Now Go To the Engine Compartment Step 12 Mark the position of the outer cable in the control valve bracket. Step 13 Unsnap the cable clamp by pulling forward and to the left. Note: This will help maintain proper cable adjustment. If you install the new cable in the exact same position as the old one, the need for further adjustment will likely be eliminated.
Step 14 Unhook the inner cable from the control valve lever. Step 15 Note the routing of the cable under the dashboard so you will know where to route the new cable. Grommet Step 16 Have an assistant remove the cable by pulling it through the firewall from under the dash.... Step 16 Continued... while you feed the cable through the grommet from the engine compartment. Caution: Be careful not to damage the grommet.
Step 17 Select this end of the new cable to pass through the firewall grommet. Step 18 Feed the cable though the fire wall grommet. Step 19 While feeding the cable through the firewall grommet, have an assistant gently pull the cable and route it the same as the original cable. Step 20 Flex the cable slightly downward and connect it to the temperature control lever.
Phillips Screwdrive Step 21 Position the outer cable in the cable clamp in the exact same position as the original one. Step 22 Tighten the cable clamp using a phillips screwdriver. Note: The screw driver must be inserted through the radio bracket bolt hole. Mark Step 23 From under the hood, connect the inner cable to the control valve lever. Step 24 Position the outer cable according to the mark made earlier.
Step 25 Snap the cable adjustment clamp into locking position. Note: Since this is a new cable, locking the clamp may require a bit more force than normal. Step 26 Position the climate control assembly back into position and install the (2) mounting screws. Step 27 Reconnect the back light to the faceplate. Step 28 Position the faceplate over the control levers and snap it into place.
Step 29 Install the (4) control lever knobs. Step 30 Slide the temperature control lever back and forth between HOT and COOL. The lever should work smoothly throughout full travel. If it binds, check the cable for kinks or misrouting or lever interference. Step 31 With the temperature control lever in the COOL position, the temperature control valve lever should be all the way up (or closed). If it is not, unclip the cable adjustment clamp, move the cable and control valve lever all the way up, and re-clip the cable clamp. Step 32 Replace the radio bracket and radio (or stereo) in reverse order of removal.
Step 33 Reconnect the negative battery cable. Step 34 Start the engine. If the engine is not at operating temperature, let it run until it is, usually about 20 minutes. With the temperature control lever in the HOT position the heater and defrost should blow warm air. Congratulations!!! You have successfully installed a temperature control cable. We hope these instructions were helpful. Thanks for shopping at Low Range Off-Road.
As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F 8am-5pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 04/16/13 Copyright 2013 Low Range Off-Road, LC All Rights Reserved