by Scale of the Problem
Fires are among the most serious safety issues, and it is now worth paying attention to a new recall. It concerns 39,536 Kia Sorento SUVs manufactured in 2021–2023.
According to the National Highway Traffic Safety Administration, “the wiring of the HVAC fan motor may be insufficient, which could lead to a fire.”
The agency added that, due to a suspected quality issue at the supplier, the connection between the fan motor resistor and the connector may overheat.
Conditions for the Hazard
This seems to occur only under specific conditions: when the climate control system is activated, the fan speed is set to the third level, and the ignition is on. Although the conditions are quite specific, the government agency noted that in rare cases, this could cause a fire.
The problem is linked to the company Aptiv, which reportedly used a thinner wire than required. Owners may notice the problem if the fan motor stops working, a burning smell or melting appears. Another sign could be smoke coming from the vents.
Investigation and Identified Causes
Kia first learned about the problem last fall after a report of a fire and a “hot rubber smell” in a 2023 Sorento LX model. The manufacturer bought back the vehicle and launched an investigation, which included X-ray analysis of the damaged fan motor resistor and the attached wiring harness. The investigation was later expanded to “warranty wiring harnesses and resistors with localized melting.”
After months of work, Kia was unable to determine the root cause. However, they identified “manufacturing deviations due to quality control, including a wire thinner than specified.” This is suspected to have contributed to the overheating.
Preventive Measures and Consequences
In total, Kia identified 25 vehicles with localized melting of the connector. There was also one localized connector fire and another vehicle fire. Fortunately, there have been no reports of accidents or injuries.
To fix the problem, dealers will replace the wiring harness and the fan motor resistor. These components will be supplied by a different supplier, and notification letters to owners are expected in November.
This recall highlights the importance of proper quality control in supply chains, especially when it comes to vehicle safety. Although the conditions for a fire are quite specific, even minor defects can lead to serious consequences. The implementation of component replacement measures and the change of supplier demonstrate that the manufacturer takes the problem seriously and aims to prevent further incidents.
