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'06 Kia Sportage a/c gremlin #4486556
08/12/17 01:31 PM
08/12/17 01:31 PM
Joined: Mar 2016
Posts: 775
Cincinnati, OH USA
CincyDavid Offline OP
CincyDavid  Offline OP
Joined: Mar 2016
Posts: 775
Cincinnati, OH USA
I was gifted a '06 Kia Sportage a couple of years ago from the original purchaser (my parents) with 135k miles on it and no fan motor or a/c function. The dealer had quoted $950 to change the fan motor and resistor and fix some melted wires at the resistor. I replaced the fan motor and resistor myself,with new Kia/Hyundai parts, and instead of trying to replace the huge multi-plug connector at the resistor, just crimped-on spade connectors and plugged into the resistor. Twice since, the connectors and wires have melted and things have quit working. What the heck is creating so much amperage/heat that there is heat damage periodically? It has 165k miles now and won't last forever, but I'm getting tired of digging around under the dash annually fixing wires.


06 Kia Sportage EX greenish gold(ugliest color ever)
11 Jeep Grand Cherokee Limited HEMI Mineral Gray
14 Honda Accord LX metallic black
17 VW Jetta SE black
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4486604
08/12/17 02:39 PM
08/12/17 02:39 PM
Joined: Dec 2006
Posts: 7,654
Toronto, Canada
KrisZ Online happy
KrisZ  Online Happy
Joined: Dec 2006
Posts: 7,654
Toronto, Canada
I would check if the blower motor fuse wasn't replaced with a higher amperage one. The fuse should blow well before any damage to the wires occurs.
Besides, that do you have any other electrical anomalies? Maybe there is a short somewhere?


2015 Dodge Grand Caravan-27k miles.
2006 Mazda 3-163k miles
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4486611
08/12/17 02:58 PM
08/12/17 02:58 PM
Joined: Jun 2003
Posts: 5,921
Illinois
SHOZ Offline
SHOZ  Offline
Joined: Jun 2003
Posts: 5,921
Illinois
Too small of wire or lug. OE is usually just big enough and with any age corrosion builds up and then starts to heat things up. It will never be the same without new wire ends. Many crimp on connectors too are steel with tin plate. Not what you want. Go for brass or tin plated copper and rated or the amperage.

The problem could be on the toehr end of the wire too.

Using a volt meter set on millivolts check the reading on both ends of the circuit if you can with the power on. Should be low reading. you can also check the ohms and it too should be low, under .2 and be sure to touch the leads together and deduct this from your reading.

Any pictures?


2008 Hyundai Accent 1.6L 5 sp manual hatchback
2010 Hyundai Genesis Coupe Track 2L Turbo 6sp manual
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4486645
08/12/17 03:52 PM
08/12/17 03:52 PM
Joined: Jun 2017
Posts: 110
FL, USA
shurguywutt Offline
shurguywutt  Offline
Joined: Jun 2017
Posts: 110
FL, USA
yes pics plz. I would solder and shrink wrap the connections if possible, this will minimize any resistance/future corrosion. are the fuses blowing? the oem wires should be sufficient as long as your new fan and resistor are to oem spec.


2008 Pilot 2WD J35Z1 148k
Maxlife Blend 10w-30
FRAM Ultra Synthetic
Fumoto F106SX
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4486766
08/12/17 07:02 PM
08/12/17 07:02 PM
Joined: Sep 2015
Posts: 1,528
USA
mk378 Offline
mk378  Offline
Joined: Sep 2015
Posts: 1,528
USA
The resistor is cooled by air flow from the fan. So restricted air flow from a mouse nest, etc. in the duct could lead to overheating.

Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4489014
08/15/17 07:49 AM
08/15/17 07:49 AM
Joined: Mar 2016
Posts: 775
Cincinnati, OH USA
CincyDavid Offline OP
CincyDavid  Offline OP
Joined: Mar 2016
Posts: 775
Cincinnati, OH USA
Taking a pic will be a trick...it's up under the dash. Soldering under there would be a trick too. Of course this wouldn't be in a convenient spot.

I never checked the fuse(s), I'll do that too. Guess it might be time to break out my handy voltmeter and see what's really going on.

The kid who drives it is going back to college today and won't have a car, so I'll have more time to investigate. great ideas from everyone, I'll let you know what I discover.


06 Kia Sportage EX greenish gold(ugliest color ever)
11 Jeep Grand Cherokee Limited HEMI Mineral Gray
14 Honda Accord LX metallic black
17 VW Jetta SE black
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4489731
08/15/17 09:35 PM
08/15/17 09:35 PM
Joined: Jun 2017
Posts: 110
FL, USA
shurguywutt Offline
shurguywutt  Offline
Joined: Jun 2017
Posts: 110
FL, USA
Also, the fuse should blow way before wires and connections melt and fail... Maybe the fuse is too big for whatever reason... Just some things to check.


2008 Pilot 2WD J35Z1 148k
Maxlife Blend 10w-30
FRAM Ultra Synthetic
Fumoto F106SX
Re: '06 Kia Sportage a/c gremlin [Re: CincyDavid] #4489753
08/15/17 10:04 PM
08/15/17 10:04 PM
Joined: May 2012
Posts: 1,400
Georgia
AVB Offline
AVB  Offline
Joined: May 2012
Posts: 1,400
Georgia
Either the resistor is over heating or the connections are. GM had the same problem on a lot of trucks. It is not likely the fuse in this case. It is probably a combination of the coils in the resistor heating up the terminals and the wire connections being a little undersized. You have two heat sources in one location.

Last edited by AVB; 08/15/17 10:10 PM.

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