This procedure covers the removal and replacement of the blower motor control module (also called the blower resistor or power transistor) located in the HVAC system of the 2016-2024 Hyundai Tucson with 2.5L I4 engine.

Warnings

Tools required

Parts

• Blower motor control module (power transistor) × 1 — Use OEM specification
• Thermal compound/paste (if not pre-applied) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and turn off ignition
2. Wait at least 2 minutes after turning off ignition to allow airbag system to discharge
3. Open passenger door and set aside floor mats to protect interior
4. Gather all tools and new blower motor control module
5. Verify new module matches old module connector configuration before beginning disassembly

Procedure

1. 1

   Access glove box area
   Open the glove box fully. Remove any contents from the glove box compartment. Locate the glove box stoppers on both left and right sides - these are plastic tabs that prevent the glove box from opening beyond its normal range.
2. 2

   Lower glove box
   Squeeze the sides of the glove box inward to disengage the stoppers from their slots. Gently lower the glove box down past its normal range until it hangs freely. This exposes the area behind the glove box where the blower motor control module is located. You do not need to fully remove the glove box.
3. 3

   Locate blower motor control module
   Looking up into the area behind the glove box on the passenger side, locate the blower motor control module. It is a rectangular metal finned heat sink mounted to the HVAC housing, typically positioned on the right side of the blower motor housing. The module will have a wire harness connector attached to it.
4. 4

   Disconnect electrical connector
   Locate the electrical connector on the blower motor control module. Press the locking tab on the connector and pull it straight out from the module. You may need to wiggle it slightly while pulling. Do not pull on the wires themselves, only on the connector body.
   ⚠Do not force the connector - ensure the locking tab is fully depressed before pulling
5. 5

   Remove module mounting bolts
   Using a 7mm socket or nut driver, remove the mounting bolts securing the blower motor control module to the HVAC housing. There are typically 2-3 bolts. Note the position and orientation of the module before removal for proper installation of the new unit.
6. 6

   Remove old module
   Carefully pull the blower motor control module away from the HVAC housing. Note that thermal compound or paste may be present between the module and the housing for heat transfer. Inspect the mounting surface on the HVAC housing for any debris or old thermal paste buildup.
7. 7

   Clean mounting surface
   Clean the HVAC housing mounting surface where the module contacts using a clean lint-free cloth. Remove any old thermal compound completely. Ensure the surface is clean and dry before installing the new module. Vacuum any debris that may have fallen into the area.
8. 8

   Prepare new module
   Inspect the new blower motor control module and verify it matches the old unit. If thermal compound is not pre-applied to the new module, apply a thin even layer to the contact surface of the module that mates with the HVAC housing. Do not use excessive paste as this can impede heat transfer.
9. 9

   Install new module
   Position the new blower motor control module in the same orientation as the old unit. Align the mounting holes and ensure the module sits flat against the HVAC housing. Install the mounting bolts finger-tight first to ensure proper alignment.
10. 10

    Torque mounting bolts
    Using a torque wrench, tighten the blower motor control module mounting bolts to specification. Tighten in a cross pattern if there are multiple bolts to ensure even pressure and proper thermal contact with the housing.
    ⚠Proper torque is critical for heat dissipation - overtightening can crack the module housing, undertightening can cause poor thermal contact and premature failure
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Push the electrical connector firmly onto the blower motor control module until you hear or feel a positive click indicating the locking tab has engaged. Gently tug on the connector to verify it is fully seated and locked in place.
12. 12

    Restore glove box
    Raise the glove box back to its normal position. Squeeze the sides inward slightly and align the stoppers with their slots on both sides. Release the sides to allow the stoppers to engage. Verify the glove box opens and closes normally and stops at the correct position.

Reassembly

1. Ensure all electrical connections are fully seated and locked
2. Verify glove box operates normally and stoppers engage properly
3. Return any items to glove box compartment
4. Replace floor mats if removed

Verification

• Turn ignition to ON position without starting engine
• Turn the blower motor fan speed control to each position (low, medium-low, medium, medium-high, high) and verify the blower operates at each speed without unusual noise or burning smell
• Verify smooth transitions between fan speeds without hesitation or surging
• Check that airflow volume increases appropriately with each speed setting
• Turn blower to OFF position and verify it stops completely
• Test both fresh air and recirculation modes to ensure proper operation
• Listen for any unusual sounds such as grinding, squealing, or buzzing that might indicate improper installation
• After 5-10 minutes of operation, check the area for any burning smell which could indicate electrical issues

More procedures for this vehicle