Small Pinched Wire Causes Kia to Dismantle New Telluride Interiors | Carscoops

      Two Kia Tellurides required complete floor harness replacements after wiring was pinched behind a speaker, leading to electrical shorts.

      The dealer was instructed by Kia to undertake the entire floor harness replacement, which is estimated to take between 7 to 12 hours.

      This significant measure highlights Kia’s cautious strategy regarding electrical reliability.

      Sometimes, even the tiniest components can lead to considerable troubles. This is evident with the rod bearings in a BMW E60 M5, the signaling cable in a Jeep Grand Wagoneer, or, in this recent case, wires positioned behind a speaker in the Kia Telluride. However, unlike the Jeep and the BMW, the Kia did not necessarily need such an extensive repair to rectify the problem. Nonetheless, they opted for this approach to ensure the job was completed properly. We have all the insights from the 20-year-old technician who handled the task.

      Introducing Emily L., a dedicated Kia technician who has a passion for Miatas, recently worked on a Telluride in her shop. At first glance, everything seemed fine with the vehicle, which only had 10 miles on the odometer and was there for a pre-delivery inspection. Emily, however, is thorough. During her inspection, she observed that the left turn signal was flashing rapidly while the rear lamp, tail light, and license plate lights were non-functional.

      Diagnosing the Issue

      “After conducting some tests, I discovered that one of the wires showed resistance of 0.1 ohms when it should have been 0.0 ohms. This indicates a short to ground, which corresponded with the error code. The wire runs directly to the ICCU from the left rear tail lamp,” Emily explained to Carscoops.

      Not long after, a second Telluride presented similar issues. Emily disassembled part of the interior near the taillight and identified the problem in both vehicles: a segment of wires pinched behind the left rear speaker housing. The pressure was sufficient to strip the insulation, causing the ground wire to contact the power wires and produce the faults.

      A Lengthy Repair

      Interestingly, simply releasing the pinched wires restored full functionality. Emily reported the situation, and Kia opted to replace the entire floor harness instead of applying a quick fix. This task is quite extensive, requiring the removal of seats, carpets, trim, and large sections of the interior. Emily spent about 12 hours performing this repair the first time.

      In comparison, fixing the small damaged area with butt connectors and heat shrink would have taken less than an hour. While there might have been a risk of introducing electrical resistance and triggering another fault, it is more probable that it would have permanently resolved the issue. Kia’s formal strategy in this instance, while extreme, guarantees long-term reliability and reduces the chance of similar shorts occurring in the future.

      A Pricey Caution

      Although potentially frustrating for technicians and undoubtedly expensive, the automaker's insistence on complete harness replacements in these instances demonstrates a commitment to ensuring the vehicles are free from defects. It also serves as a reminder of how a minor manufacturing error can escalate into a significant repair issue in modern vehicles that rely heavily on electronics.