Charge Port Assembly

This procedure covers removal and replacement of the charge port assembly on a 2023 Chevrolet Bolt EUV, including high-voltage de-energization, connector removal, and proper reinstallation with torque specifications.

Warnings

Tools required

Parts

• Charge port assembly × 1 — Use OEM specification
• Charge port door assembly (if damaged) × 1 — Use OEM specification
• Charge port gasket/seal × 1 — Usually included with charge port assembly

Preparation

1. Park vehicle on level surface and ensure it is not plugged in to charging equipment
2. Place wheel chocks and engage parking brake
3. Ensure vehicle is in Park mode and powered off completely
4. Allow vehicle to sit for at least 10 minutes after last use to allow high-voltage components to cool
5. Gather all required tools and safety equipment including high-voltage insulated gloves and multimeter
6. Review high-voltage safety procedures specific to GM electric vehicles

Procedure

1. 1

   De-energize high-voltage system
   Turn vehicle completely off and remove key fob from vehicle. Open hood and locate the high-voltage service disconnect under the hood near the front of the vehicle. Remove the service disconnect cover by releasing the retaining clips. Pull the high-voltage service disconnect handle straight up to disconnect. Wait a minimum of 5 minutes for capacitors to discharge. Use a high-voltage multimeter to verify zero voltage across the disconnect terminals.
   ⚠️Do not proceed until voltage is confirmed at zero. Orange cables carry up to 400V DC.
2. 2

   Disconnect 12V battery negative terminal
   After high-voltage system is de-energized and verified, disconnect the 12V battery negative terminal using a 10mm wrench. Isolate the cable away from the battery post to prevent accidental reconnection.
3. 3

   Access charge port area
   Open the charge port door on the driver side front fender. From inside the front wheel well, remove the inner fender liner fasteners (combination of push clips and T25 Torx screws) to access the rear of the charge port assembly. Partially fold back the liner to expose the charge port mounting area.
4. 4

   Remove charge port door
   Open the charge port door fully. Remove the two cover screws securing the charge port door hinge assembly to the fender. Carefully disconnect the door release cable by depressing the retaining clip and sliding the cable end from the door mechanism. Remove the door assembly and set aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
5. 5

   Disconnect charge port wiring harness
   Don high-voltage insulated gloves. Locate the wiring harness connectors at the rear of the charge port assembly. Depress the locking tabs on the low-voltage connector(s) for the charge port indicator lights and proximity sensor and disconnect. Note connector positions for reassembly.
6. 6

   Disconnect high-voltage charging cable
   While wearing high-voltage insulated gloves, locate the orange high-voltage connector at the charge port. Remove the connector protective cover. Remove the high-voltage connector bolts using the appropriate socket. Carefully separate the high-voltage connector from the charge port assembly, ensuring not to damage the connector seals or pins.
   ⚠️Verify system is de-energized before touching orange cables. Use only insulated tools.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
7. 7

   Disconnect proximity sensor connector
   Locate the sensor connector near the charge port assembly. Remove the sensor bolts securing the proximity sensor to the charge port housing. Disconnect the sensor connector by depressing the locking tab and carefully pulling the connector free.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
8. 8

   Remove charge port mounting fasteners
   From the wheel well area, locate the charge port mounting bolts (typically 3-4 bolts) securing the assembly to the vehicle body. Remove these mounting bolts while supporting the charge port assembly to prevent it from falling. Remove the bracket bolts if equipped that secure any support brackets.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
9. 9

   Remove charge port assembly
   Carefully pull the charge port assembly rearward through the fender opening from the wheel well side. Guide all wiring harnesses through the access holes as you remove the assembly. Inspect the mounting area and gasket surfaces for damage or debris. Clean mounting surfaces with a clean, lint-free cloth.
10. 10

    Install new charge port assembly
    Install new gasket/seal onto the new charge port assembly if not pre-installed. Guide the charge port assembly into position from the wheel well side, routing wiring harnesses through the appropriate access holes. Align the mounting holes with the body mounting points. Install mounting bolts finger-tight initially to allow for alignment adjustment.
11. 11

    Torque mounting fasteners
    Torque the charge port mounting bolts to specification in a cross-pattern to ensure even seating. Install and torque any bracket bolts to secure support brackets. Verify the charge port is flush with the fender surface and properly aligned with the door opening.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

    Bracket Bolts20 Nm (15 lb-ft)
12. 12

    Reconnect high-voltage connector
    While wearing high-voltage insulated gloves, carefully align the high-voltage connector to the charge port terminals. Ensure connector is fully seated with no gaps. Install high-voltage connector bolts and torque to specification. Install the connector protective cover and verify it is fully seated.
    ⚠Inspect connector pins for damage before connecting. Damaged pins can cause charging failures or arcing.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
13. 13

    Reconnect sensors and wiring
    Install the proximity sensor to the charge port housing and torque sensor bolts to specification. Reconnect all low-voltage connectors for indicator lights and sensors, ensuring all locking tabs fully engage. Verify all connectors are fully seated and routed properly to avoid pinching.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
14. 14

    Reinstall charge port door
    Reconnect the door release cable to the door mechanism, ensuring the cable end snaps fully into place. Position the charge port door assembly and align the hinge with the mounting holes. Install the cover screws and torque to specification. Test door operation to ensure smooth opening and proper latching.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
15. 15

    Reinstall fender liner and reconnect batteries
    Reinstall the inner fender liner, securing all push clips and Torx screws. Reconnect the 12V battery negative terminal. Reinstall the high-voltage service disconnect by pushing the handle down firmly until it clicks into place. Install the service disconnect cover. Close the hood.

Reassembly

1. Ensure all high-voltage connectors are properly torqued and protective covers are installed
2. Verify charge port door opens and closes smoothly and latches securely
3. Confirm all wiring harnesses are routed properly and not pinched or stressed
4. Double-check that fender liner is fully secured to prevent road debris access

Verification

• Power on the vehicle and check for any warning lights or fault codes related to the charging system
• Use GM diagnostic software to verify charge port communication and proximity sensor function
• Test charge port door release function from both the charge port button and vehicle interior controls
• Perform a test charge with Level 1 or Level 2 charging equipment to verify proper charging initiation and indicator light function
• Inspect charge port area for proper sealing and verify no gaps around the assembly
• Verify charge port locking function engages when vehicle is locked (if equipped)
• Check for any high-voltage fault codes and clear if repair-related codes are present

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

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