4 Minutes
What happened
Kia America is recalling certain 2021–2023 Sorento LX crossovers after discovering that the HVAC blower motor resistor connection can overheat when the fan is set to speed three. In rare but serious cases the overheating can lead to localized melting and even a fire inside the instrument panel. The issue was traced to a wiring assembly supplied by Aptiv (part number 91100-R5140), where some harnesses used a thinner-than-intended wire gauge due to production variances.
How the defect was found
The U.S. investigation began in October 2024 after a third-party cause-and-origin report involving a 2023 Sorento described a burning rubber smell from the vents followed by a fire. The report indicated the fire started in the passenger-side instrument panel, forward of the glove box near the blower motor. Kia repurchased the vehicle and performed X-ray and lab analyses. Engineers determined the fault originated at terminal two of the connection between the blower motor resistor and the wiring harness, the circuit responsible for fan speed three.
Scope and scale
Kia’s follow-up checks identified a total of 25 vehicles with localized connector melting, one verified connector fire and one vehicle fire. Fortunately, there have been no reported injuries or accidents linked to this defect. For the U.S. market the recall covers 39,536 Sorento LX units built at Kia’s West Point, Georgia assembly plant (KMMG) from September 10, 2020 to December 29, 2023.
Remedy and timeline
Kia is asking affected owners and lessees to have dealers replace both the blower motor resistor and the blower motor resistor circuit harness at no cost. Interim notifications will be mailed by November 24, 2025, and final remedy notifications are expected by December 31, 2025. Kia notes the problem did not persist into the 2024 Sorento because that model year uses a different HVAC system design.
Why this matters
- Potential fire risk from overheating wiring inside the dash.
- Occurrence tied to one specific harness part number: 91100-R5140.
- Recall affects Sorento LX models built at Kia’s West Point (KMMG) plant.
West Point is a high-volume facility that produces the Sportage, Sorento, EV6 and EV9 for multiple markets, with roughly 350,000 vehicles rolling out annually. The recall underscores how a single supplier variance can ripple through production and trigger wide-ranging safety actions.
Practical advice for owners
If you own a 2021–2023 Sorento LX, especially one built during the affected window, watch for these warning signs: persistent rubber or burnt smells from the vents, unusual smoke or visible melting near the glove box, and HVAC fan behavior anomalies—notably at fan speed three. If you suspect a problem, stop using the HVAC fan at that setting and contact your local Kia dealer to schedule an inspection and free repair.
"Kia is taking corrective action and will replace the resistor and harness free of charge for affected customers," a Kia America spokesperson said.
Model context: the Sorento LX
The LX trim of the 2021–2023 Kia Sorento was offered with a naturally aspirated 2.5-liter inline-four that produces 191 horsepower and 182 lb-ft (247 Nm) of torque. A turbocharged option remains available, but many buyers prefer the naturally aspirated engine for its better fuel economy in city and combined cycles. With front-wheel drive, the NA 2.5-liter Sorento posts roughly 25–26 mpg depending on the testing cycle—solid economy for a mid-size family crossover.
For buyers and enthusiasts tracking safety recalls, this case is a reminder that even well-regarded mainstream models can require supplier-driven fixes. If you think your Sorento might be affected, check Kia’s recall lookup with your VIN or speak with an authorized dealer.
Source: autoevolution
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