Introduction
This guide will show you how to replace an air conditioner actuator on a VE Commodore. These actuators commonly fail on Series 1 vehicles and have been seen to fail on Series 2, however a revised unit is now being used.
There are multiple actuators behind the dashboard controlling modes, temperatures and air sources. Our guide will show you how to identify the faulty actuator and the steps to replace it.
HVAC = Heating, Ventilation and Air Conditioning
Common symptoms
- Vents stuck in a certain mode such as feet, face or demister.
- Loud clicking noise behind the dashboard when changing modes or temperature
- Heating / Cooling not working properly. Often permanently on heat or cold.
Difficulty Rating
Tools/Parts Required
- Trim Removal Tools
- Screwdrivers
- Replacement Air Conditioner Actuator – Sold by AutoInstruct
Guide
How To Identify The Faulty Actuator
Multiple actuators can be found on both the left and right sides of the dashboard. The same actuator units are used regardless of its purpose. Let’s go through some troubleshooting steps below:
- Attempt a HVAC System Relearn
- It’s possible that your actuators are not actually faulty but have ‘forgotten’ which position they are in. The relearn process runs all actuators for 10-15 seconds, allowing them to calibrate their positions.
- To do this first close your doors and turn the radio off. You’ll need to listen to the motors and they’re very quiet.
- Turn the Ignition to ‘on’ but do not start the car. Press and hold the rear demister button until you hear the actuators moving. After 10-15 seconds the actuators will stop and the system will be calibrated. Test the air conditioner system and check if your problem still exists. Be sure to cycle through each mode and heat / cool.
- If the problem still exists or you heard loud clicking noises during this process, it is very likely that an actuator is faulty. Proceed to the next step.
- Identifying the Faulty Actuator
- If you heard loud clicking noises during the relearn process this will help with identification. Run the relearn again and listen for the clicking. Is it on the passenger or drivers side? Listen around the footwell area on both sides and you should be able to determine where it was louder. We now need to access that actuator.
- If no clicking was heard and you still suspect the actuator is at fault, visual identification may be required to see if the motor and HVAC arms are moving when the relearn is in progress. This will involve trim removal from the drivers and/or passenger side of the vehicle. We’ll run through this process below.
- Note: There is an electrical interlock between the AIR RECIRC function and the HOT/COLD mixing function. If the system detects a malfunction in the AIR RECIRC, the HOT/COLD mixing actuator is disabled. This fault is indicated by the LED on the RECIRC button blinking.When you run “relearn, if the HOT/COLD actuator is not moving, this does not necessarily indicate that the actuator has failed. It might be that the RECIRC system has failed, and the interlock has disabled the HOT/COLD mixing actuator. Confirmation of the fault is indicated by the blinking LED on the RECIRC button.
- It is possible to have multiple actuators fail! Keep this in mind when performing your assessment.
Step 1
System Overview
There are 4 HVAC actuators in the system, each one is identical
- Air Recirculation Door Actuator – Located above the blower fan and controls the recirculation function.
- Floor Vents – Upper left side of centre console (Passenger Side)
- Heat/Cool – Lower left side of centre console. Uses interconnecting levers to control the butterfly valve inside the heater box
- Face Vents – Upper right side of centre console (Drivers Side)
Step 2
Drivers Side Actuator
The drivers side actuator which controls the air directions between feet, face, demister is usually the faulty unit. It is often identified as the air conditioner being ‘stuck’ on feet or demister modes. The process below outlines the actuator replacement procedure.
Using a trim removal tool, pop off the side trim piece. There are three clips, one on each corner.
Step 3
- Wedge your fingers behind the lower section of the trim and firmly pull upwards as shown by the red arrows.
- With the bottom clips released use a gentle hinging and pulling motion to release the top clips on both sides of the steering wheel. Pull away as shown by the orange arrows.
- Be careful releasing the clips as the trim will drop downwards. It is quiet heavy.
Step 4
As the trim is released you will need to unplug the headlight switch. Push on the clip and unplug.
Step 5
Unscrew the OBD port as circled and pull downwards on the kick panel trim. There are approximately 5 clips holding this trim in place.
Step 6
Remove the air conditioner ducting which is held in place by two screws.
Step 7
You’ll now need to locate the actuator. Look up beside the headunit and high in the dashboard your will see the actuator as pictured.
To verify the actuator is faulty, run the relearn process as described previously. If you feel or hear the actuator clicking, or the HVAC arms are not moving, the actuator is probably at fault and will need to be replaced.
Step 8
Replacing the actuator is a very difficult process due to the location in the vehicle. There are two screws (Red circles) holding the actuator in place, and one alignment pin (Green circle) to ensure the actuator is in the correct position. There is also a green wiring plug you will need to disconnect.
The bottom screw is relatively easy to access with a small stubby screwdriver or a ratcheting screwdriver set.
The top screw is extremely difficult to remove as there is limited space to operate. You may find yourself lying upside down in the footwell and painstakingly turning the screw millimetre by millimetre.
Once both screws are removed the motor will simply pull off from the HVAC arm. The HVAC arm may fall off, so take note of its orientation and position to simplify reinstallation.
Step 9
The replacement actuator (Which you can purchase directly through us at AutoInstruct – We’d appreciate the support!) can now be installed into the vehicle.
Firstly reinstall any HVAC arms that may have fallen loose, then slide the arm onto the actuator – It can be in any position. Next place the actuator onto the alignment pin and begin to install the lower screw.
Commence installation of the upper screw, checking alignment and position of the actuator and HVAC arms.
Once both screws are tightened, connect the wiring harness and perform a HVAC relearn. You should now see the actuator moving smoothly without any clicking noises. When the relearn is complete, test operation between feet, face and demister. Keep in mind we have removed the ducting on the drivers feet!
Step 10
Passenger Side Actuator
Remove the kick panel below the glove box. This is held in place by five clips.
Step 11
Remove the two screws which are now visible.
Step 12
Remove the five remaining screws. The far left and right screws are hidden behind small covers.
Step 13
The glovebox will now be loose. simply pull outwards and disconnect the boot release plug and loom.
Step 14
Pull outwards and down the side trim piece. It will unclip.
Step 15
Now we can see the passenger side actuator.
To verify the actuator is faulty, run the relearn process as described previously. If you feel or hear the actuator clicking, or the HVAC arms are not moving, the actuator is probably at fault and will need to be replaced.
Step 16
Remove the faulty actuator by unplugging the electrical connector, unscrewing the two screws and pulling the drive gear off the HVAC arm. This actuator is much easier to access compared to the drivers side.
Replace the actuator with a new unit. Screw into place and reconnect the wiring loom.
Once both screws are tightened, connect the wiring harness and perform a HVAC relearn. You should now see the actuator moving smoothly without any clicking noises. When the relearn is complete, test operation between feet, face and demister. Keep in mind we have removed the ducting on the passengers feet!
This Post Has 222 Comments
Hi, Have a 2010 VE Calais. Air con fan stopped blowing onto passenger & drivers feet, but front & side vents were ok. I done a re-learn, it then stopped blowing through all vents, except windscreen demister. It still blows hot & cold though, but demister vents only. The relearn sounds like a winding sound though, more so clicking.
If I need a new actuator, will it be the drivers side, as the noise is from the centre vents when relearn?
Hello, This typically sounds like the drivers side actuator. I would investigate that first.
hi would u have any idea how to replace the recirclation door?
We don’t sorry. This would involve full disassembly of the HVAC Box.
Hi, I have a MY09.5 SSV Commodore. I didn’t have any problems with my HVAC system, but upon hearing of the relearn procedure, I stupidly decided to try it. No clicking noises were heard. And now all of a sudden I have the only blowing hot air out of the passenger and rear vent problem. So I have to agree with some of the above posts, do not try this. It seams running this internal program can corrupt the system somehow. I have read on other forums that disconnecting the battery overnight has fixed this. So before I start pulling things apart I am trying this tonight and will update you guys tomorrow how this goes. I also have one of the cheap OBDII Bluetooth scanners and it did not show any codes.
Hi Mick, The relearn will only cause issues if something is truely wrong with the system – E.g a broken actuator (Clicking noises are not always audible). The re-learn looks for the endpoints of the actuators, and runs into issues if the actuator is faulty. The cheap OBDII Scanner will not display HVAC error codes, only powertrain.
I’ve recently replaced my cabin filter, when I did this I noticed there was a dome like cover over the blower motor. So this morning after reconnecting the battery and still having the issue, I thought this would be the easiest thing to check, assuming this domed door is what controls the re-circulation I checked to see if it moved when going from fresh air to recirculate. It did not. If therefore this does control the recirculate function, should I be seeing the led in the recirculate button blinking as you described under identifying the fault? Because it is not flashing. And if the actuator for this door is faulty how do I access it to replace it?
Cheers
It’s difficult to diagnose this remotely because any number of issues could lead to a certain component not working or operating. E.g the LED may not flash. We don’t have a guide for that actuator, however it’s quite hard to access as it sits on top of the blower motor, behind the glovebox.
Hi Guys, it turns out the problem was the pivot on the re-circulation door, which was broken (a common occurrence apparently). Where the actuator engages with the pivot is a weak point. So when I did the relearn it detected this and, in turn disabled the mixer door. So anyone who has done the relearn and then has the passenger side and rear vents blowing hot air, this could very well be the problem. The door can be replaced through the engine bay underneath the plenum cover. It is not however an easy job and nearly cost me my sanity lol. You can order a new recirc door through your holden dealer. The part number is 92246499.
hey mate, how do you remove the plenum cover?
Hi, I have a 08 Vauxhall vxr8 (VE com I believe). This article is great and I’m sure I have a faulty actuator as air con is stuck on drivers side whereas passenger side operates as normal. Not ideal in Scotland when I’m trying to defrost this time of year. Once I’m sure which one is faulty, would you please post me one to Scotland?
That’s correct – Please send us an email and we will sort you out! Click on ‘Contact Us’