Converting to Automatic Climate Control for the Holden VE Commodore
- Document Information
- A supplementary guide showing how to convert the HVAC system to support DZ Climate Control Operation.
- Vehicle: Holden Commodore (VE)
- Copyright Owner: Matthew Jones (Matti Jones) (ZerOne)
- Document Visits: 39540
- Created: Mon Aug 27, 2012 8:30 pm
- Revised: Mon Aug 27, 2012 9:19 pm (Rev 12)
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Firstly, a big thankyou must go out to the following,
To MsEnj, for providing the required information and feedback regarding part numbers, required sensors, installation pictures, wiring and testing information,
when performing a complete Single to Dual Zone Climate Control Conversion.
MsEng was the first person (in the world) to perform this operation on a VE Omega Commodore, and her willingness to share her knowledge,
as well as help others is greatly appreciated !
Another big thankyou must also go out to MartinM, for his work scouring workshop manuals, tracing electrical schematics, and calculating the required resistor values when simulating the required sensors for Dual Zone Operation, (Without actually fitting the required sensors).
Without his help, we would all still be getting ripped off, and paying far too much for colour head unit conversions.
This document contains supplemental instructions that are required when upgrading a VE Series I Non Colour LCD Radio and HVAC head unit, to the VE Series I Colour Radio and HVAC head unit, as well as fitting a Holden IQ unit to a Series I VE Commodore.
When carrying out this conversion, the existing Heating and Ventilation vehicle hardware and wiring will not be compatible with the new Series I Colour LCD Radio and HVAC head unit (Or Holden IQ Head Unit).
The problem is specifically caused by the Colour LCD head unit / Holden IQ unit expecting the vehicle to be fitted with all the required sensors, wiring, and modules required for Dual Zone Climate Control Operation.
Without carrying out these extra steps, the new colour LCD head unit / Holden IQ unit will log diagnostic code errors, and the heating, ventilation, and air conditioning controls will not function.
What is Involved ?
There are two different methods used to get the colour head unit / Holden IQ unit functioning in a vehicle without the dual zone climate control fitted 1) Obtain and modify a HCE/HCM module, by fitting 4 resistors to the HCE/HCM main board to simulate the required Dual Zone Climate Control Sensors, and program the HCE/HCM EEPROM if required.
2) Obtain and fit a Dual Zone Climate Control HCE/HCM module (Or program a Single Zone HCE/HCM module), as well as fit and wire the required Dual Zone Climate Control sensors to the vehicle.
Pros and Cons of Method 1
Pros : By far the quickest, easiest and cheapest method to get the HVAC functions working when fitting a colour LCD headunit to a non DZ climate control vehicle.
Requires only a HCE Module to be programmed for Dual Zone Operation, as well as four resistors to be fitted to the HCE/HCM main board.
Cons : This method will not give you true Dual Zone Climate control functions.
Any passenger air temperature settings when the HVAC system is set to operate in DZ mode will be ignored.
Furthermore, the system will not operate as a true climate control system. I.E. because four of the required sensors have been bypassed, the climate control system will always assume the same ambient temperatures inside and outside the car, and will also assume the same amount of sunlight is available facing the windscreen, regardless if it is daytime, nighttime, summer or winter.
Basically, the system will not automatically adjust the temperature or the direction of the incoming air to determine how best to cool or heat the interior based on the selected temperature.
Pros and Cons of Method 2
Pros : Allows for full Dual Zone Climate Control operation, including displaying the outside air temperature readings, setting the passenger air temperature to a different setting to the drivers air temperature, and full automatic climate control functions.
Cons : This method is by far the most expensive and most difficult method to get the colour LCD head unit HVAC functions working.
It requires a Dual Zone HCE to be sourced, (Or a single zone HCE to be programmed for DZ operation), and the cabin ambient air temperature sensor, the Climate control specific sunload sensor, the passenger air temperature flap regulator motor,exterior ambient temperature sensor, and extra wiring (that will not exist) to be fitted to the vehicle.
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Tools Required
Phillips head screwdriver, flat headed screwdriver, soldering iron, solder,
2mm Hex Key, and quite possibly a lot more
Parts Required - Method 1
3 x 2.6K Ohm Resistors (Can be bought from Jaycar Electronics in Australia, RS Components, Element14, etc)
1 x 5.7K Ohm Resistor (Again, can be bought from Jaycar Electronics in Australia, RS Components, Element14, etc)
Optional - A spare HCE/HCM module preferably from a vehicle with Dual Zone Climate Control.
Parts Required - Method 2 1 x Dual Zone HCE module will need to be sourced from a vehicle with DZ climate control fitted
(I.E. SS-V, Berlina, Calais, Calais V, Statesman, and short wheel base HSV models).
1 x Exterior ambient air temperature sensor.
1 x Interior ambient air temperature sensor, complete with ducting hose to be fitted to the heater box
1 x Dual Zone Climate control sunload sensor (To replace the existing light sensor located on the top middle of the dash)
1 x Passenger side temperature flap regulator motor.
Wiring plugs and connectors (If possible, otherwise modifications to existing wiring plugs will be required).
Optional - A spare HCE/HCM module preferably from a vehicle with Dual Zone Climate Control.
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To simulate the single zone, Non Climate Control HVAC operation, the Outside ambient temperature, cabin temperature, and the windscreen drivers and passengers sun load sensor readings need to be faked.
For single zone, non climate control models, in the absence of the required sensors, this value is faked via software, for an ambient temperature reading of 23.5 degrees Celsius.
When using a Dual Zone HVAC Control Module, the module expects to receive readings from these sensors, thus when upgrading to the colour LCD headunit, you will need to either fit these sensors, or fake the readings for these sensors via connecting resistors to the HCE hardware.
Internal Ambient Sensor 2.6K (giving an approximate cabin temperature of 23.5 degrees C).
This resistor needs to be fitted across the X2 Connector pins A1 & A2
Outside Ambient Sensor 5.6K Ohms (giving an approximate outside air temperate of 23 degrees C)
This resistor needs to be fitted across the X2 Connector pins A7 & A8
To simulate the left and right windscreen sun load sensors 2.6K Ohm Resistors need to be fitted.
The first resistor needs to be fitted across the X2 Connector pins A1 and A4.
The second resistor needs to be fitted across the X2 Connector pins A1 and A5.
The simplest method to acheive this is to solder the resistors directly on to the HVAC Control Module main board.
To do this,
1) Remove the two Hex screws used to hold the HVAC Control Module units plastic cover in place.
2) Unclip the single plastic clip located at the top of the HVAC Control moduel unit used to hold the plastic cover in place.
3) Remove the HCE/HCM plastic cover to access the main baord.
4) Next, You will need to remove the main board from the HCE/HCM plastic cover,
To do this, attempt to pull the main board gently away from the plastic backing, by pushing against the heatsink assembly,
and sliding the main board upward and away from the plastic cover.
Once the main board has been removed, flip the board over to reveal the backside of the PCB as shown in the below image.
Next, grab two 2.6K Ohm resistors, and solder one side of the resistors to the Terminal labelled GND.
(Please Note, in the images below, I have placed electrical tape underneath these resistors to ensure that they do not short out against any exposed tracks, or solder joints on the main board).
Next, solder the other leg of one resistor to the terminal labelled 4.
This will simulate the drivers side sun load sensor for the front windscreen.
Next solder the other leg of the second resistor to the terminal located to the right of terminal 4.
This will simulate the passenger side sun load sensor for the front windscreen.
Next, solder the third 2.6K Ohm resistor between the Pins labelled 1 and 2, as shown in the following image
This will simulate the internal cabin air temperature sensor.
Finally, solder the 5.7K Ohm resistor between the Pins Labelled 7 and 8 (Located directly beneath Pins 1 and 2).
This will simulate the Outside Ambiant Air Temperature Sensor.
Once you have fitted all the required resistors, use some electrical tape to cover the resistors to ensure that the do not short against anything.
Essentially, when you have completed the above steps, you will have connected the following,
Fitted a 2.6K Resistor between Pin A1 and Pin A2 on the X2 Connector to bypass the Cabin Ambient Temperature Sensor.
Fitted a 5.6K Resistor between Pin A7 and Pin A8 on the X2 Connector to bypass the Outside Ambient Temperature Sensor.
Fitted a 2.6K Resistor between Pin A1 and Pin A4 on the X2 Connector to bypass the Drivers Sunload Ambient Light Sensor.
Fitted a 2.6K Resistor between Pin A1 and Pin A5 on the X2 Connector to bypass the Passengers Sunload Ambient Light Sensor.
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Parts required
1 x Dual Zone Sun Load Sensor - 25713063 - $55.00
1 x External Ambient Temperature Sensor - 09152245 - $35.00
1 x Interior Cabin Temperature Sensor - 92171917 - $12.20
1 x Interior Sensor Duct Hose - 92192336 - $4.20
1 x Passenger Side Blend Door Actuator - ?????? - $????
? x A number of Pins that can be removed from a spare wiring connector.
(Sunload Sensor is shown on the left, the Interior Ambient Temperature Sensor is shown in the middle, and the external ambient temperature sensor is shown on the right).
Step 1, you will need to get access to the side of the vehicles airbox to fit the required parts.
The above image shows where you will need to fit the Interior Cabin Temperature Sensor, and the Passenger Side Blend Door Motor Actuactor.
All the mounting points and the toothed door drive connection for the second actuator are on the single zone unit already. Even the aspirator holder is moulded in.
The large red circle in the image above is the mounting hole for fitting the Interior Cabin Temperature Sensor.
With non climate control vehicles, this hole will be sealed, and will require cutting a suitable hole to fit the interior cabin temperature sensor.
Once the required hole has been cut, glue the Cabin Temperature Sensor in place.
The small blue star shaped hole is for fitting the passenger side blend door motor actuator.
(With the tiny green painted hole being the actuator mounting screw holder point, used to screw the actuator in to place)
NOTE : Before you fit the passenger side blend door actuator, you will need to seperate the drivers and passenger air temperature blend doors.
For single zone HVAC vehicles, the passenger air temperature blend door is physically connected to the drivers blend door.
Thereby giving the passenger side of the vehicle the same air temperature as the drivers side of the vehicle.
To seperate the drivers and passengers blend air temperature doors, you will need to access the inside of the HVAC air box assembly through the upper center stack ventilation ducts.
NOTE : You may find it easier to access the blend doors by removing the center support beam for the left and right center stack ducting.
The image below shows the easiest location to insert your hand / arm to gain access to the drivers and passengers air temperature blend doors.
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Once you have physically fitted the Cabin ambient temperature sensor, the new sunload sensor, and the exterior ambient temperature sensor, you will need to add the required wiring to the vehicle, to connect these sensors to the HVAC Control module.
Firstly, locate the HVAC Control module X2 Wiring connector.
This will be a green coloured connector, and will be connected to the HVAC Control module just beneath the 2 Pin Fan Motor Wiring Connector.
Unplug the X2 Wiring Connector from the HVAC Control module, and release the connector pin latch using a small flat bladed screwdriver.
(See the above image for more details).
This will allow further pins to be added or removed to the X2 Wiring Connector.
Next, Using the above image as a pin location guide, locate the socket / holes for Pins 1 and 2.
Wire the Cabin Ambient Temperature Sensor to these locations. (The polarity of the Interior ambient temperature sensor is not important, so it does not matter which wire goes to Pin 1 or 2.
Next, locate Pins 7 and 8 on the X2 connector, and wire the external ambient temperature sensor in to these locations.
(Again, it does not matter which wire goes to Pin 7 or Pin 8, as the external ambient temperature sensor does not have a polarity).
Next, wire the ground wire for the sun load Sensor to Pin 1 on the X2 Connector.
(The ground wire for the sun load sensor is coloured ????, and is connected to Pin X on the sun load Sensor Wiring Connector shown below).
Connect the X Wire from the sun load sensor (Coloured ????), to Pin 4 of the HVAC Control Module X2 Wiring Connector.
Next, connect the X Wire from the sun load sensor (Coloured ????), to Pin 5 of the HVAC Control Module X2 Wiring Connector.
Finally, you will need to connect the Passenger side blend door motor actuator to the HVAC Control Module X connector.
PLEASE NOTE : THE ABOVE INFORMATION IS CURRENTLY ON MY TODO LIST - MATTI
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Please Note : The following steps are only required if you will be using a HVAC Control Module from a single zone vehicle.
If you are using your existing HVAC Control Module module, or if you are using a HCE/HCM module removed from a vehicle with a single zone (Non Climate Control System), then you will need to write new binary data to the HVAC Control Module EEPROM module.
To do this, you will require an EEPROM programmer that is capable of writing to a 93C66xw EEPROM.
Both the KeeProg and MCU-Mall GQ-4X EEPROM programmers listed in our EEPROM programming for beginners document are suitable, however the GQ-4X EEPROM programmer requires the EEPROM to be removed from the HCE/HCM module in order to be programmed.
To program the HCE/HCM EEPROM, you will first need to open and remove the top cover the HVAC Control Module unit to access the main board.
Please Note : You will not need to remove the main board from the plastic housing to access the EEPROM.
For further information on how to open the HCE/HCM cover, see the above instructions.
Once you have removed the cover, locate the EEPROM chip using the Image below as a guide.
If you are using the KeeProg EEPROM programmer, you will be able to write to the chip without removing it from the board, using a 3M Clip.
Next, using a 3M Clip, place the clip as shown in the image above, taking note the location of the red stripe of the 3M Clip socket matches up with Pin 1 on the EEPROM chip.
Finally, connect the 3M clip to your KeeProg EEPROM programmer, and upload the following binary file to the EEPROM chip.
FILE TO BE ADDED
The above file will convert your HVAC Control module from a Single Zone non climate control module, to a Dual Zone automatic climate control module.
Once the file has been successfully uploaded, unplug the EEPROM programmer, and test the HCE/HCM unit.
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Once you have completed the Dual Zone Climate Control Coversion (Both Method 1 and Method 2),
You should then proceed to conduct a Actuator Learn Proceedure.
The actuator learn proceedure will completely open, and completely close all the HVAC actuators, as well as obtain the actuator position values, ensuring that the HVAC sensors have been calibrated correctly.
To perform this calibration,
1) Turn the Ignition switch to the On position (But do not start the engine).
2) press and hold the rear demister button untill you hear the HVAC system actuators moving.
The actuator motors are reasonably quiet, so it is recommended that you have the windows and doors closed whn performing this calibration.
3) Once the actuators have ceased moving, your HVAC system will now be calibrated.