Kia High Contact Resistance at Connector

Kia EV charger cable or plug becomes very hot to the touch during charging.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Worn or oxidized contacts in Type 2 plug, Loose crimp connections inside plug, Undersized or damaged cable conductors, Vehicle inlet contacts worn or contaminated

How to Fix / Troubleshooting

Safety first: If the plug is too hot to hold comfortably, stop charging and allow it to cool. Overheating can lead to fire.

  • 1. Stop charging: Press stop on the charger or disconnect the vehicle, then turn off the breaker if necessary.
  • 2. Inspect plug: Look for discoloration, melted plastic, or deformed pins on the Type 2 connector. Any visible damage means the cable must be replaced.
  • 3. Clean contacts: If no damage is visible, gently clean the plug with a dry cloth and compressed air. Do not use abrasives or liquids.
  • 4. Test at lower current: If your charger allows, reduce the charging current and monitor plug temperature. Persistent heating indicates a mechanical issue.
  • 5. Replace cable or vehicle inlet: If overheating continues, replace the Kia charger cable assembly. If multiple cables overheat, have the vehicle inlet inspected by a Kia dealer.
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Repair Difficulty

Medium 3/5

Required Part

Type 2 Charge Cable Assembly
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