This procedure replaces the HVAC mode door actuator, which controls air flow direction between defrost, vent, and floor positions in the climate control system.

Warnings

Tools required

Parts

• Mode door actuator × 1 — Use OEM Hyundai part number for 2016-2024 Tucson

Preparation

1. Park vehicle on level ground and turn off ignition
2. Disconnect negative battery terminal and wait 3 minutes for airbag system to discharge
3. Set climate control to OFF position before beginning work
4. Remove all items from passenger side footwell area
5. Allow HVAC system to cool if vehicle was recently operated

Procedure

1. 1

   Remove passenger lower trim panel
   Using trim panel removal tools, carefully pry out the lower passenger side kick panel. Start at the rear edge and work forward. Remove two Phillips screws securing the lower dash trim panel below the glove box. Gently pull the panel away from the dash to release the retaining clips.
2. 2

   Remove glove box assembly
   Open the glove box fully. Squeeze the sides of the glove box inward to release the damper stops. Continue lowering the glove box and disconnect the glove box light electrical connector if equipped. Remove the glove box completely by releasing the hinge pins on each side.
3. 3

   Locate mode door actuator
   Using a flashlight, locate the mode door actuator on the right side of the HVAC unit. It is a small rectangular motor mounted to the air distribution housing with a gear mechanism visible on one side. The actuator will have an electrical connector attached.
4. 4

   Disconnect actuator electrical connector
   Press the locking tab on the mode door actuator electrical connector and carefully pull the connector straight off. Note the connector routing for reinstallation. If access is difficult, use needle-nose pliers to depress the locking tab.
5. 5

   Remove actuator mounting screws
   Remove the three Phillips screws securing the mode door actuator to the HVAC housing. Support the actuator with one hand while removing the final screw to prevent it from falling.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
6. 6

   Remove actuator from linkage
   Gently rotate the actuator counterclockwise approximately 90 degrees to disengage the drive gear from the mode door linkage arm. Carefully pull the actuator away from the housing. Do not force the linkage arm or apply excessive pressure to the plastic components.
   ⚠The mode door linkage arm is plastic and can break if forced. Rotate the actuator slowly while applying gentle outward pressure.
7. 7

   Prepare new actuator
   Compare the new actuator to the old unit to verify correct part. Check that the drive gear rotates freely and is in the neutral/center position. If the new actuator has a shipping lock tab, remove it according to manufacturer instructions.
8. 8

   Install new actuator
   Align the drive gear of the new actuator with the mode door linkage arm. Rotate the actuator as needed to mesh the gear teeth properly. Gently push the actuator into position on the HVAC housing while rotating clockwise to fully engage the linkage.
9. 9

   Secure actuator mounting screws
   Install the three Phillips screws to secure the actuator to the HVAC housing. Start all screws by hand first, then tighten in a cross pattern to the specified torque. Ensure the actuator is fully seated against the housing before final tightening.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
10. 10

    Reconnect electrical connector
    Plug the electrical connector onto the new actuator until the locking tab clicks into place. Gently tug on the connector to verify it is fully secured. Route the wiring harness in the original position to avoid pinching.
11. 11

    Reinstall glove box assembly
    Position the glove box and align the hinge pins on each side. Push the hinge pins into their mounting points. Reconnect the glove box light connector if equipped. Close the glove box partway and verify the damper stops engage properly when squeezing the sides inward.
12. 12

    Reinstall passenger trim panels
    Position the lower dash trim panel and press firmly to engage all retaining clips. Install the two Phillips screws to secure the panel. Reinstall the passenger side kick panel by pressing firmly at all clip locations until fully seated.

Reassembly

1. Reconnect negative battery terminal and tighten securely
2. Reset clock and radio presets as needed
3. Enter radio security code if prompted

Verification

• Turn ignition to ON position without starting engine
• Turn on climate control system and cycle through all mode settings (vent, bi-level, floor, defrost, floor-defrost)
• Verify airflow changes direction appropriately for each mode setting
• Listen for smooth actuator operation without clicking, grinding, or binding noises
• Start engine and verify mode door continues to operate correctly with blower on all speeds
• Check for proper airflow temperature control in all modes

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