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
I am having issues with my 2009 SS VE sportswagon when I put the aircon on or heater and change the direction of air flow to the floor vent there is no air it just comes out the front? Can anyone tell me what the issue is, is it the Actuator? If not any ideas how to fix this problem.
Thanks
Hi Joe, That definitely sounds like the actuator. Try run through the re-learn procedure and listen for clicking noises. That will identify the actuator at fault.
Hi, I have a 2009 VE Commodore Sedan. The Re-circulation was not working and I carried out the RE-Learning procedure. Now there is only Hot Air blowing even when the cold air is selected. Any Ideas please? Is the Re-circulation and Temperature controlled by the same actuator?
Thanks
Hello, these are different actuators, and I have never seen a faulty recirculation door before. Not sure how to fix that unfortunately.
Thanks for that! I removed the glovebox and found two actuators, one in the position indicated in your diagram (that is not functioning) and one above that is functioning. I will replace the faulty actuator (it’s probably the Hot / Cold control) and chase down the re-circulation door functionality!
Great to hear! You’re welcome to purchase a replacement temp actuator through us!
Hey mate I’m going through the same problem. I have changed the hot and cold Actuator, the recirculation actuator, even tried changing the radio and climate control modual with my mates ones and still can’t get the arm to move off hot unless I manually move it. Did you end up finding the problem with yours
Hi Team,
Some great info here. I recently had my trusty local repairer change the faulty / broken actuator on the drivers side for air vent control on my 2010 VE Omega dual fuel ute. (217000klms).
I am now having an issue with the HVAC fan intermittently working. It either works Ok with variable speed control or absolutely nothing. All other modes function as required. Last time it did spin I did notice that it was a bit noisier than normal, mainly at higher speeds.
Any ideas on what could be the problem?
Cheers
Hi Matt, It could be the bearings in the fan that have failed. There is also a common issue with a loose connection on the HVAC Control Facia. Try push firmly on the trim around the HVAC buttons and see if the fan speed control works again.
Hi Team,
Have pushed firmly all around the HVAC facia panel with no luck getting the fan to run.
I have selected all modes, stopped and started the vehicle and checked the under bonnet fuses still with no response.
Would it be wise to check for voltage at the fan motor connection, if so how do I access this?
Cheers
Hi Matt, The fan motor is located directly behind the glovebox. If you remove the glovebox you should see a cylindrical shaped end with connectors.
No problem, checked supply voltage at connector, removed the fan to clean and service – all sorted
Thanks
Hi Matt, awesome outcome in the meantime! Thanks for posting the steps, we might add them to this guide.
Update: Followed the instructions to remove glove box , yay – fan blower is right in front.
Checked for variable voltage at plug connection, showing .084vdc on minimum to 12.55vdc on high speed fan selection through the dial.
Removed 3 screws + 2 cable loom retainers to remove the fan unit from the blower assembly.
Removed service cover from fan unit to expose internal brushes / armature etc. Bearings at this stage seem fine and smooth.
Spun the unit and blew out a lot of carbon dust with compressed air followed by a squirt of electrical cleaner. Continued to blow out any excess before hooking up the plug connection and retrying operation – all OK.
Reinstalled fan unit and reassembled glove box etc. Retried full function test of HVAC – all OK.
I think a new fan unit will be needed in the not to distant future……
Matt
Ve commodore. I have done what u said and no more clicking noise BUT now i only have heating. No air con. Only blows hot air on heating and cooling. Why?