Vehicle fires are among the most alarming safety concerns, and Kia has recently announced a new recall that highlights this risk. The recall affects 39,536 Sorento SUVs built for the 2021 through 2023 model years. According to information provided by the National Highway Traffic Safety Administration (NHTSA), the issue stems from a potential defect in the heating, ventilation, and air conditioning (HVAC) system. Specifically, the wiring harness for the HVAC blower motor may not be up to proper standards, creating a situation where overheating could occur and, in some cases, lead to a fire.
NHTSA explained that the concern is tied to the connection between the blower motor resistor and its connector. Because of what appears to be a supplier quality control issue, this connection can overheat under certain conditions. The problem has only been observed when the climate control system is turned on, the ignition is active, and the fan speed is set to level three. Although these are very specific circumstances, the risk of fire—even if rare—makes the defect a serious one. The supplier in question, Aptiv, is said to have used a thinner gauge wire than required, which likely contributed to the overheating hazard.
For vehicle owners, several warning signs could point to this issue. These include the blower motor suddenly ceasing to operate, the presence of burning or melting odors inside the cabin, or even visible smoke emerging from the air vents. Kia first became aware of the defect in the fall of last year, when a report surfaced regarding a 2023 Sorento LX that experienced a fire accompanied by a “hot rubber smell.” Following the report, the company bought back the affected SUV and began a detailed investigation. This included x-ray analysis of the burned blower motor resistor and adjacent wire harness.
As the inquiry progressed, Kia also examined additional returned parts from warranty claims. These parts showed localized melting around the resistors and wire harness connectors. Even after months of analysis, Kia could not determine a single definitive cause. However, the company did identify inconsistencies in manufacturing quality, particularly variations in wiring thickness, which were strongly suspected to have contributed to the problem. Altogether, Kia documented 25 cases where connectors displayed localized melting, along with one incident of a connector fire and one full vehicle fire. Fortunately, no accidents or injuries have been linked to the defect.
To resolve the issue, Kia dealers will replace both the blower motor resistor and the wiring harness in all affected Sorento SUVs. These replacement parts will come from a different supplier to ensure the problem does not recur. Owners of the impacted vehicles can expect to receive official notification letters beginning in November, with repairs carried out free of charge.