heater control wiring melted

[rebecca.joyc]

So i posted another topic about the blower motor.

Right now I'm stuck, we took the heater controls off and the connector behind the middle switch and it was melted, even on the inside where the 8 connectors are.
here is the link to the heater control and the back part
Heater Control Rio 03 04 05 2003 2004 2005 - eBay (item 370539730464 end time Oct-02-11 09:16:04 PDT)
, and on the back, it's the middle one that is the issue. that round peice was a little bit melted but im confused about the wire that connects into there, does anyone know what it's called? i cant even find any pictures of it, im having a hard time finding a used part, so my dad can fix it.
please help

[Kevster]

I am not familiar with the Kia controls, but I see in the schematic you should have a 6 pin connector at the back of the fan speed switch. That should connect to the blower resistor (4 pin connector). I don't know where exactly Kia located the resistor, but it is usually installed on the blower housing somewhere so the blower air cools it in normal use. You'll see the connector but the main body of the resistor is inside the housing. My Rio is away at the dealers so I can't look right now. Kia parts.net lists that heater control at about $215 USD, so $40 bucks on ebay is a deal. The resistor is about $40 USD, and I see some on ebay for $35-38, so not much savings there. The blower motor is $125 from Kiapartsnet. You may also need a relay....since something overheated and it may have affected everything in the circuit. Buying a used blower on ebay may be risky. I'd slap in that new(er) control off ebay...a new resistor..and a NEW blower and relay (IF you have confirmed it as bad). I'm thinking you're gonna want it reliable, when your Canadian winter hits. Good luck and sorry I am not much help here. Never had to work on my heater controls, yet.

[Kevster]

Ask the guy selling the controls if he'll cut the wiring harness out(of the donor car) for you, so you have new connectors that aren't all fried/melted. Then you can splice them into your harness. Worth a shot...

[rebecca.joyc]

well i bought that heater control off ebay, and then i went to pick a part and cut the pigtail wires out of an 04 rio. My dad's going to splice the wires and connect that, and hopefully that fixes it, i don't want to have to replace the blower fan, getting behind the glove box looks like a PITA.

[Kevster]

Let us know how it works out. I'd be a little concerned about your blower motor or resistor being bad and causing a high amp draw (but not quite blowing the fuse) and the resulting heat is melting things. Try a smaller fuse in the blower circuit, (factory is 30 amp), like a 20 amp fuse to have it "blow" before the wiring or harness does. If it quickly blows a 20A fuse try a 25A and go from there. Better to buy a few fuses than replace the controls again. Better yet, get a DC ammeter and see what the actual load is on the fan circuit at all 4 speeds.

[ronjohn]

Hey rebecca, like kevster says let us know it turned out. I responded to your first post glad it got you in the right direction did your resistor unit melt also i wasn't sure from your post or was it just the switch assembly. If you can get your hands on a dc clamp on ammeter you can measure the current draw on the blower at all speeds to see if its ok. If you get in a jam yes i know winter is comming and you being up in canada you need the heat you could hot wire the blower and bypass the resistor unit put in a toggle switch and fuse it properly but you would only have high speed just to get you through the winter the switch is a known issue usually if the connector has melted thats due to a poor connection or the switch contacts I see it at work all the time when switch contacts or wires are loose the connection heats up and degrades the insulation on the wire . I hope your new switch works out keep us informed I wish you luck with it Reguards Ronjohn

[rebecca.joyc]

Originally Posted by Kevster

Let us know how it works out. I'd be a little concerned about your blower motor or resistor being bad and causing a high amp draw (but not quite blowing the fuse) and the resulting heat is melting things. Try a smaller fuse in the blower circuit, (factory is 30 amp), like a 20 amp fuse to have it "blow" before the wiring or harness does. If it quickly blows a 20A fuse try a 25A and go from there. Better to buy a few fuses than replace the controls again. Better yet, get a DC ammeter and see what the actual load is on the fan circuit at all 4 speeds.

I believe we put a 20A in the blower fuse. I have some extra 25's and 30's so I'll keep it in mind when we put it all back together. Thank you

[gschwaller]

I have a question about the heater/fan controls in a 2003 Rio. I just bought it and tonight was the first time I drove it at night. The fan speed control, temp control, and selector controls are not lit. This is pretty unhandy. Should they be lit and if so, are there serviceable bulbs in the control unit??

[ronjohn]

Yep there should be a bulb or two behind them to illuminate them. Kia Global Information System (KGIS) for service materials and more (Schematics) free to USA residents just have to register check it out to get them bulbs replaced or figure out why they don't work, good luck. Reguards Ronjohn