Kia Overheating / Thermal Damage

Kia home charger emits a burning smell or shows discoloration on the housing during or after 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

Loose internal terminals causing arcing, Overloaded or undersized supply cable, Failing contactor with high contact resistance, Blocked ventilation causing heat buildup

How to Fix / Troubleshooting

Safety first: Immediately turn off the charger at the breaker if you smell burning or see smoke. Do not use the charger until inspected.

  • 1. Power off immediately: Switch off the dedicated EV charger breaker and leave the unit off.
  • 2. Visual inspection: Once cooled, look for melted plastic, discoloration, or deformation on the charger housing and cable.
  • 3. Professional inspection: Have a qualified technician open the charger to inspect terminals, contactor, and wiring for signs of overheating or arcing.
  • 4. Correct wiring and replace damaged parts: Tighten or re-terminate any loose connections, upgrade undersized wiring, and replace any heat-damaged components with Kia-approved parts.
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Repair Difficulty

Professional Required 5/5

Required Part

Internal Wiring and Contactor Assembly
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