Some Kia Sorento SUVs are facing a new safety warning: a problem with the HVAC system may cause the electrical wiring to overheat, increasing the risk of a fire.
The National Highway Traffic Safety Administration (NHTSA) has issued recall 25V-649 for all the 2021–2023 Sorento models produced at Kia’s Georgia Plant. The risk is that heat may build up where the blower motor resistor connects to its harness when the fan is running and the ignition is on.
The early warning signs are burning-plastic smell, smoke around the climate controls, or a blower that doesn’t. But no worries, Kia will fix the issue at no cost as soon as it is confirmed that your VIN is affected.
Are you one of the affected ones?
The HVAC system is the source of the issue. Some wiring connections may use a wire gauge that’s actually thinner than it was intended at the blower resistor connector due to differences in supplier quality.
What can happen? Specific overheating when the cabin fan runs (especially at mid- to high speeds) with the ignition on because thinner wire can withstand less heat. Even though it is not that common, that heat has the potential to spread and cause smoke or a fire.
The recall 25V-649 covers the 2021–2023 Sorento (LX trim referenced) manufactured at the Georgia Plant between September 2020 and December 2023. And although Kia estimates that only about 1% of vehicles may actually have the defect, up to 39,000 vehicles are included in that chance. Owner notices are expected to arrive in October to November 2025, and dealer repair actions started on September 26, 2025.
How did it happen in the first place?
Supply chains for modern cars are complex. In this particular case, it seems that a Tier-2/3 supplier’s quality failure allowed a wrong wire gauge to enter the harness assembly. The problem could have become apparent later in because internal validation did not put enough stress on the connector to replicate worst-case thermal loads. Little changes like this can avoid regular testing—until the weak point is revealed after several months of fan use.
Kia will replace what’s not working correctly for free. Refunds are also possible if you have already paid for repair related to this issue.
If you notice smoke, a burning smell, or the blower starts failing, then it’s a good idea to park outside and away from other cars or buildings until the repair is finished.
Once you’ve been noticed, schedule your dealer visit ASAP and use the NHTSA website or Kia’s portal to get the VIN check linked to recall 25V-649.
The electrical wiring’s appropriate heat tolerance is will be restore, and the hot spot at the connector that was causing overheating will be eliminated.
Simple steps for owners
If you have a 2021–2023 Sorento, follow these 3 easy steps:
- Run the VIN check for recall 25V-649 and wait for your notification.
- Make an appointment for the free repair (replacement of the blower resistor and harness) at an authorized dealer.
- Keep an eye out for any early warning signs, like smoke, burning plastic smell, or a malfunctioning blower, and park outside until the issue is fixed.
Recalls improve trust among the clients and protect drivers. A tiny connector inside the HVAC system has the potential to cause a major issue in this case, but the solution is simple, quick, and free of charge.
By verifying your VIN and updating your system, you can eliminate the possibility of a fire, fix the electrical wiring overheating point, and maintain the safety of your Kia Sorento. And go to the NHTSA listing for recall 25V-649 for official information and status updates.