Charging Cable - Level 1

This procedure covers the replacement of the Level 1 charging cable (120V EVSE) on a 2023 Chevrolet Bolt EUV, including removal of interior trim panels, disconnection of charging port wiring, and installation of a new Level 1 charging cable assembly.

Warnings

Tools required

Parts

• Level 1 Charging Cable Assembly × 1 — GM Part Number 42695809 or equivalent
• Charging port connector seal × 1 — Use OEM specification
• Cable routing clips × 3 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered off and key fob is removed from the vehicle
3. Open hood and disconnect 12V negative battery terminal
4. Wait minimum 5 minutes for high-voltage system capacitors to discharge
5. Open charging port door on driver side front fender
6. Verify no charging cable is connected to the vehicle
7. Remove rear cargo area floor panel to access charging cable storage compartment

Procedure

1. 1

   Verify high-voltage system de-energization
   Using a high-voltage capable multimeter with insulated gloves, verify that the high-voltage system is de-energized by checking voltage at the charging port terminals. Voltage should read 0V. If any voltage is present, do not proceed and consult a certified EV technician.
2. 2

   Remove charging port cover and access panel
   From the driver side front fender area, remove the charging port door. Remove the three cover screws securing the charging port access panel using a Phillips screwdriver. Carefully pull the access panel away from the fender to expose the charging port assembly.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect charging port electrical connector
   Locate the high-voltage connector at the rear of the charging port assembly. Press the orange safety lock tab and slide it to the unlock position. Squeeze the connector release tabs and carefully pull the connector straight back from the charging port. Remove the two high-voltage connector bolts securing the cable to the port assembly.
   ⚠️Ensure system is de-energized before touching high-voltage connectors. Orange components indicate high-voltage.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
4. 4

   Remove charging port mounting bolts
   Remove the four charging port mounting bolts securing the charging port to the fender bracket. Support the charging port assembly while removing the final bolt to prevent it from falling.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
5. 5

   Release cable from routing clips
   Working from the charging port area toward the rear cargo compartment, release the charging cable from all routing clips along the left side of the vehicle. Note the routing path for reinstallation. There are typically 8-10 clips securing the cable along the undercarriage and inner fender well.
6. 6

   Remove cable bracket bolts
   Locate the cable support bracket near the rear cargo area pass-through. Remove the two bracket bolts securing the charging cable bracket to the vehicle frame. Carefully lower the bracket and cable assembly.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
7. 7

   Disconnect rear harness connector
   In the rear cargo area, locate the connector where the Level 1 charging cable connects to the vehicle's charging management system. Press the connector lock tab and separate the connector halves. Remove the two connector bolts if equipped.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
8. 8

   Remove old charging cable assembly
   Carefully pull the complete charging cable assembly through the vehicle routing path, noting any grommets or pass-through seals. Remove the cable from the vehicle and inspect all mounting points for damage or corrosion.
9. 9

   Install new charging cable assembly
   Route the new Level 1 charging cable through the same path as the original, starting from the rear cargo area toward the charging port. Ensure all grommets and seals are properly positioned. Install new cable routing clips as needed to match original configuration.
10. 10

    Connect rear harness connector
    In the rear cargo area, connect the new charging cable to the vehicle's charging management system connector. Ensure the connector locks fully into place with an audible click. Install connector bolts if equipped and torque to specification.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
11. 11

    Install cable bracket
    Position the cable support bracket near the rear cargo area and align with mounting holes. Install the two bracket bolts and torque to specification using a torque wrench.
    Torque spec

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

    Reconnect charging port
    At the charging port location, install the new charging port connector seal if provided. Connect the high-voltage connector to the charging port, ensuring it seats fully. Install the two high-voltage connector bolts and torque to specification. Slide the orange safety lock tab to the locked position.
    ⚠Verify connector is fully seated before torquing bolts. Improper connection can cause charging faults.
    Torque spec

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

    Install charging port assembly
    Position the charging port assembly into the fender bracket, aligning all four mounting holes. Install the four charging port mounting bolts and torque to specification in a cross pattern.
    Torque spec

    Charging Port Mounting8 Nm (6 lb-ft)
14. 14

    Reinstall access panel and trim
    Position the charging port access panel and align with the fender. Install the three cover screws and torque to specification. Close the charging port door and verify it operates smoothly.
    Torque spec

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

    Reconnect battery and initialize system
    Reconnect the 12V negative battery terminal. Power on the vehicle and allow the charging system to initialize. Check for any warning lights or messages on the instrument cluster related to the charging system.

Reassembly

1. Reinstall rear cargo area floor panel and ensure all trim pieces are secure
2. Verify all cable routing clips are properly engaged and cable is not pinched or kinked
3. Ensure charging port door opens and closes smoothly without obstruction

Verification

• Connect a Level 1 charger to the vehicle and verify charging initiates properly
• Check instrument cluster for confirmation of charging status and no fault codes
• Verify charging port indicator light illuminates correctly (green for ready, blue for charging)
• Perform a test charge for at least 15 minutes to ensure stable operation
• Inspect all connection points for proper seating and no signs of arcing or overheating
• Verify cable routing does not interfere with any moving components or suspension travel

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