Thanks alot man,it seems you have all the answersSee the Service Manual...
https://www.mediafire.com/folder/cvrt1rfoso8t8/Service_Manuals
And this thread...
http://www.suzuki-forums.com/1g-199...itara/43016-2000-vitara-2-0l-heater-core.html
This can be done for a 03-05 model with the new dash design too? The Service Manual is for 99-02 modelThe evaporator should be behind the glove box - I don't think you need to remove the dash to replace it.
I can confirm that,today i managed to install the evaporator without removing the dash. It was installed from the compartment located behind glove box,it a easy task (2-3 hours of work).The reason I said should is because I'm not 100% certain - that's where it is on the earlier model GVs and most Suzukis I've worked on - it should take you no more than five minutes to confirm.