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Electrical wiring?

Tiny
02SEDONAEX
  • MEMBER
  • 2002 KIA SEDONA
  • 151,000 MILES
I have a 02 KIA Sedona, the fan switch for the front does not work. Upon taking the dash apart and trying to replace the switch I discovered the switch was burnt and melted. The wiring harness looked a little bunt and melted.

Before I spend the 900+ for the labor and whole new front dash wiring hanress. I wanted to try this, I wanted to cut the harness and try and get the clip off the old swtich. If I can get the clip off the old switch I wanted to Crimp cap and or solder the harness back back to gether.

If the wire on the clip is bad, I want to add new wire to the clip and reattach it to the main wire.

How do I test to see if the main harness is still good? Meaning after I cut the harness and expose bare wire, How can I test to make sure it has the right amount of juice? No fuses are blown or melted and everything else works. The wiring for the front fan motor and resistor both have the about right power.

Should the harness for the fan blower switch have 12V going to it? What should each wire test out at? I think it has 8-10 wires in all in differnt colors.


If all of the above fails my last plan of action is to cut the harness and solder the wires directly to the brass prongs on the new blower switch. If I can not cut the clip for the harness off the old blower switch.

Any and all help will help me. At this point I have nothing to lose, KIA doesn't sell this section of the harness. They told me I have to buy a whole new front harness. So If this fails or I mess something Up, I'll already have to replace the whole harness.

Thanks for all your help.
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Monday, September 17th, 2012 AT 5:50 PM

15 Replies

Tiny
SATURNTECH9
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Why don't you just go to pick a part and clip that connector out and buy it from them.
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Monday, September 17th, 2012 AT 5:56 PM
Tiny
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Pick a part? I don't think I have one around me or the three states around me. If the wire shorted out will the clip still be good?
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Monday, September 17th, 2012 AT 6:11 PM
Tiny
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What clip are we talking about?Also I have seen plenty of those fan switch connectors melt etc and there not be a short. It just happens over time but to be on the safe side after you fix it you check the amperage draw on the system.
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Monday, September 17th, 2012 AT 7:06 PM
Tiny
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What state do you live in?
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Monday, September 17th, 2012 AT 7:08 PM
Tiny
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I live in NH, I called Pick a part and they told me they are only in CA and I had to contact LKQonline. Com

When I say clip I'm talking about the plastic part that all the wires on the harness go into. Then the plastic clip hooks into the back of the fan switch, the brass prongs in the fan switch hook into the plastic clip. I'll try and take a photo of the old switch tonight and the new switch.

I have called all the local salvage yards and no one has a KIA in stock and the ones that do claim they don't sell that kind of thing(by thing I mean the whole harness.) Yards around here will not allow you to enter te yard, only workers are allowed in.
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Monday, September 17th, 2012 AT 7:30 PM
Tiny
SATURNTECH9
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So the clip as you call it is the connector cavitiy.I live in california and know all the pick a parts around here.I will do some research and see what I can find.
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Monday, September 17th, 2012 AT 7:38 PM
Tiny
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This is a photo of a radio harness but it will do. The black thing On the end is what i'm talking about. The main harness has that black plastic part( Or cavitiy as you call it.) That part looks melted and looks fused to the back of the old fan switch. The wires coming out of the back of the cavitiy look a little burnt but for the most part look ok.
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Monday, September 17th, 2012 AT 7:44 PM
Tiny
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Yeah yours is a square one iam waiting for some email answers to see if they have that connector used.I will let you know what I find.
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Monday, September 17th, 2012 AT 8:45 PM
Tiny
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Thank you kindly Sir.
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Monday, September 17th, 2012 AT 8:57 PM
Tiny
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Can you post a picture of the actual connector?I have a seller asking for one?
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Monday, September 17th, 2012 AT 9:20 PM
Tiny
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Yes I will try and get you one tonight, if not I will post it first thing tomorrow
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Monday, September 17th, 2012 AT 9:41 PM
Tiny
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Alright thanks.
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Monday, September 17th, 2012 AT 9:43 PM
Tiny
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Here are a few photos of it.
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Tuesday, September 18th, 2012 AT 1:14 PM
Tiny
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The photo on the left is the Right side wiring harness for the rear air/heat, but it's the same clip for both sides. The photo of the black thing is the burnt out switch on the left hand side, for the front air/heat/A/C.

I stopped being nice and used brute force, took hold of the switch and wire harness and pulled hard. It snapped off the clip and broke the side of the clip on the harness. Upon looking at the clip it looked fine, but the brass prongs on the clip looked black and burnt. Having nothing to lose I grabbed the new switch and plugged it in. Turned the knob and the blower motor came to life. So knock on wood I got it working, I just wrapped electric tape around the side that broke just to hold on it more and keep things from touching.

So as of now it's working fine, and I pray it keeps working that way. I am kinda worried as to why the switch just burnt out that bad with out the fuse doing it's job and blowing. Is this normal?

Again Thank you vary, vary, Vary much for all your help sir.
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Tuesday, September 18th, 2012 AT 1:22 PM
Tiny
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I have seen those blower switch connectors melt like that over time and blow the fuse.I just replaced the plug if it was bad enough. But usually the switch takes it the worse when they wear/short out. So if your good with for now then we will let it be.
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Tuesday, September 18th, 2012 AT 5:03 PM

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