Another car brand issued a recall for its vehicles over fire risk. According to the National Highway Traffic Safety Administration (NHTSA), Kia is recalling more than 39,000 vehicles after discovering an issue with the heating, ventilation, and air conditioning system, which could increase the risk of a fire.
The issue stems from the vehicle’s blower motor wiring harness, a portion of the HVAC system, overheating, and catching fire. The recall includes certain 2021-2023 Kia Sorento cars, according to the recall notice posted on September 25 by the NHTSA.
Here’s what you need to know about the recall.
How Many Kia Vehicles are Being Recalled?
According to the NHTSA, the recall applies to approximately 39,536 2021-2023 Kia Sorento cars. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning October 9, 2025.
What Caused the Recall?
According to the recall notice, Kia has recalled over 39,000 vehicles due to an issue with the heating, ventilation, and air conditioning (HVAC) blower motor wiring harness, which may be inadequate and could result in a fire.
Kia Investigations That Lead to the Recall
According to the safety recall report submitted on September 29, 2025, the Kia NA Safety Office engineer evaluates a third-party fire Cause & Origin report involving a 2023MY Sorento LX, reviewing a customer allegation of a hot rubber smell coming from the AC vent and subsequent fire.
The report revealed that the origin of the fire is located within the instrument panel on the passenger side, above and to the left of the HVAC blower motor. However, the cause of the fire was undetermined.
Kia North America Safety Office receives a repurchased 2023MY Sorento LX for further investigation. During further investigation, Kia engineers examined the damaged parts using X-ray analysis.
They discovered that the damage was at terminal #2 in the connection between the blower motor resistor and the wire harness. It was clear that there was damage, but the cause was still unclear.
From February 14, 2025, to March 28, 2025, Kia NA Safety Office collected more returned wire harnesses and resistors with localized melting at the connection and delivered them to Kia headquarters for further investigation.
Kia headquarters analyzed the returned parts and confirmed the localized melting damage to terminal #2, but the cause of the damage was unknown. Later, Kia HQ and the wire harness supplier work together to investigate further.
While no root cause of melting was identified, some control issues, like thinner wiring than normal, might have caused overheating when using the blower at fan speed 3 of the HVAC system.
On September 17, 2025, Kia reviewed field data and found 25 vehicles with melted connectors, one small fire at the connector, and one complete vehicle fire. Then, on September 18, Kia finally decided to recall all 2021–2023 Sorento LX vehicles due to the fire risk.
What Could be the Reasons Behind the Blower Motor Wiring Harness Catching Fire?
Several issues can lead to the blower motor wiring harness catching fire.
- Bad Blower Motor: A failing blower motor can lead to drawing excessive current, overstressing the wiring harness, and potentially causing it to overheat.
- Loose Connections: If electrical connections are poor or loose, it can create high resistance, which generates heat and can melt wire insulation, leading to a fire.
- Damaged or Corroded Wires: If wires are exposed to moisture, it can cause corrosion, leading to electrical resistance, short circuits, and overheating.
- Electrical Overload: Too much electric current in the circuit can lead to excessive heat in the wiring.
- Clogged Air Vent: Sometimes, the air vent in the blower motor gets clogged due to dirt and dust, preventing it from cooling itself and causing it to overheat.
- Wear and Tear Components: Over time, the components, such as wiring and motor, wear out, especially during hot weather, causing the fire.
Symptoms of the Blower Motor Wiring Harness Catching Fire
You have to look for these warning signs to be aware of the blower motor wiring harness catching fire.
- Burning or hot smell coming from your car’s vents.
- Smoke coming from the vents due to the melting insulation from the overheated wires.
- Inconsistent fan speeds or only works on certain speeds.
- Drawing too much current can lead to issues with other electrical components or a dead battery.
- Preventing the blower motor from working or causing it to operate at reduced capacity.
If you detect any of these symptoms, you should immediately shut down the heating and air conditioning system to prevent a potential fire. Also, call a qualified mechanic to inspect the system to diagnose the problem and ensure proper repairs are made.
Has Kia Reported Any Injuries or Accidents Due to the Issue?
Fortunately, there have been no injuries or accidents reported by Kia till now.
How Will Kia Fix the Issue?
Kia authorized dealers will replace the wiring harness and blower motor resistor, free of charge. Affected owners will receive interim notification letters about the safety risk, expected to be mailed on November 24, 2025.
Additional letters will also be sent once the final remedy is made available.
Wrapping Up
While no injuries have been reported so far, Kia isn’t taking any chances with the fire risk. If you own a 2021–2023 Sorento, you can check for the recall using the NHTSA database. However, the vehicle identification numbers involved in the recall will be searchable on NHTSA.gov beginning October 9, 2025.
You may also contact Kia customer service at 800-333-4542 for more details.
Frequently Asked Questions
1. How Many Kia Vehicles are Affected by this Recall?
Kia recalled about 39,536 vehicles, specifically certain 2021–2023 Kia Sorento models.
2. What Caused the Kia Recall?
The recall was issued due to a potential fire risk linked to the blower motor wiring harness in the HVAC system, which can overheat and catch fire.
3. What are the Warning Signs of this Wiring Harness Problem?
You may notice:
- Burning or rubber-like smell from the vents
- Smoke from the air vents
- Fan working only at certain speeds
- Strange electrical issues or dead battery
- HVAC system not working properly
4. Has Kia Reported Any Injuries or Accidents Because of this Issue?
As of now, Kia has reported no injuries or accidents related to this recall.
5. How Will Kia Fix the Fire Risk Problem?
Kia dealers will replace the blower motor resistor and wiring harness free of charge for affected vehicles.
6. How to Check If Your Kia Car Has Been Recalled
You can check for recalls using the NHTSA recall database. However, the vehicle identification numbers involved in the recall will be searchable on NHTSA.gov beginning October 9, 2025.
