A Particular Fan Setting May Cause Fires In Thousands Of Kia SUVs | Carscoops

      The 2021-2023 Sorento may have an issue with the wiring harness that could lead to various problems.

      Kia is recalling nearly 40,000 Sorento SUVs due to a wiring defect caused by a supplier error that could result in overheating, melting, and a fire. The fire risk is present only when the HVAC is operating at a certain speed while the ignition is on.

      Fires represent a significant safety concern, and there is a recent recall to take note of. This affects 39,536 Kia Sorento SUVs from the 2021 to 2023 model years.

      According to the National Highway Traffic Safety Administration, the wiring harness for the heating, ventilation, and air conditioning (HVAC) blower motor may be insufficient, potentially leading to a fire.

      The agency further explained that a suspected quality issue from the supplier may cause the connection between the blower motor resistor and the connector to overheat.

      This issue appears to arise only when the climate control system is on, the fan speed is set to three, and the ignition is turned on. Although these conditions are quite specific, the agency noted that this could lead to a fire, albeit rarely.

      The problem is attributed to Aptiv, which allegedly used a thinner gauge wire than what is required. Owners might notice issues if the blower motor fails, or if they detect a burning or melting smell. Another indication could be smoke emanating from the air vents.

      **Investigation Underway**

      Kia became aware of this problem last fall after a report of a fire and a "hot rubber smell" in a 2023 Sorento LX. The automaker bought back the vehicle and initiated an investigation, which included an x-ray analysis of the affected blower motor resistor and its wiring harness. The investigation was subsequently broadened to include “warranty returned wire harnesses and resistors showing localized melting.”

      After several months of investigation, Kia was unable to determine a definitive root cause. However, they found “production variances due to quality control issues, including the use of thinner than nominal wiring.” These factors were considered potential contributors to the overheating.

      **Fixing The Fault**

      Kia identified a total of 25 vehicles with localized melting of connectors. There was also one instance of a localized connector fire and another vehicle fire. Fortunately, there have been no reported accidents or injuries.

      To rectify the issue, dealers will replace the wiring harness and blower motor resistor. These parts will be obtained from a different supplier, and owner notification letters are anticipated to be sent out in November.