Charging Cable - Level 2

This procedure covers the replacement of the Level 2 charging cable assembly on a 2023 Chevrolet Bolt EUV, including disconnection of high-voltage components and proper torquing of all connections.

Warnings

Tools required

Parts

• Level 2 Charging Cable Assembly × 1 — Use OEM specification
• High-voltage connector seals × 2 — Use OEM specification
• Cable routing clips × 4 — Replace as needed

Preparation

1. Ensure vehicle is parked on level surface with parking brake engaged
2. Disconnect 12V auxiliary battery negative terminal and wait 2 minutes
3. Open charge port door and verify no charging cable is connected
4. Remove driver side front wheel well liner to access high-voltage service disconnect
5. Don high-voltage insulated gloves before proceeding
6. Locate and remove high-voltage service disconnect plug (orange connector behind access panel)
7. Wait minimum 5 minutes after disconnect removal for capacitor discharge
8. Use multimeter to verify zero voltage present at high-voltage terminals

Procedure

1. 1

   Access charging port assembly
   Open the charge port door fully. Remove the two charging port cover screws using appropriate socket. Carefully pull the cover away from the body to expose the internal charging port assembly and cable routing.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Disconnect charging port connectors
   Locate the low-voltage signal connector on the back of the charging port assembly. Press the locking tab and disconnect. Note the routing and orientation of all wiring for reassembly.
3. 3

   Remove charging port mounting
   Remove the four charging port mounting bolts securing the port assembly to the body bracket. Support the port assembly while removing the final bolt to prevent it from falling. Carefully pull the assembly forward to access the Level 2 cable connection.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
4. 4

   Access cable routing under vehicle
   Raise and safely support the vehicle on jack stands. Remove the underbody shield panels along the driver side to expose the cable routing from the charge port to the onboard charger module. Document cable routing path with photos.
5. 5

   Remove cable bracket fasteners
   Locate and remove all cable bracket bolts securing the Level 2 charging cable along its routing path. There are typically 6-8 brackets from the charge port to the onboard charger module. Keep all brackets and hardware organized for reinstallation.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
6. 6

   Disconnect high-voltage cable at onboard charger
   Locate the onboard charger module in the front driver side compartment. Verify again with multimeter that no voltage is present. Remove the orange high-voltage connector bolt securing the Level 2 cable to the charger input. Carefully pull the connector straight out, avoiding any twisting motion. Do not allow connector to swing and contact metal surfaces.
   ⚠️Verify zero voltage with multimeter immediately before disconnecting high-voltage connector. Orange cables carry lethal voltage if system is energized.
   Torque spec

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

   Remove additional connector bolts
   Remove any remaining connector bolts at intermediate junction points along the cable run. Note the position and orientation of each connector for proper reassembly.
   Torque spec

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

   Extract old charging cable
   Carefully route the old Level 2 charging cable out through the charge port opening, feeding it through all grommets and cable pass-throughs. Inspect all grommets and seals for damage and replace if necessary. Clean any corrosion or debris from the cable routing path.
9. 9

   Prepare new charging cable
   Unpack the new Level 2 charging cable assembly. Inspect all connectors for damage and verify proper installation of connector seals. Apply light coat of dielectric grease to high-voltage connector contact surfaces. Compare new cable routing to photos taken during disassembly.
10. 10

    Route new cable to onboard charger
    Beginning at the charge port end, carefully route the new cable through all pass-throughs and grommets following the original path. Ensure cable does not contact any sharp edges, hot surfaces, or moving components. Leave enough slack for natural movement but avoid excessive loops.
11. 11

    Connect cable to onboard charger
    Align the high-voltage connector with the onboard charger input terminal. Ensure connector is fully seated with no gaps. Install the high-voltage connector bolt and torque to specification. Verify connector lock mechanism is fully engaged.
    ⚠Ensure high-voltage connector is perfectly aligned before tightening. Cross-threading can damage expensive onboard charger module.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
12. 12

    Install cable brackets
    Working from the charger end toward the charge port, install all cable brackets in their original positions. Torque all bracket bolts to specification. Ensure cable is properly secured in each bracket clip without excessive tension or compression.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)
13. 13

    Install charging port assembly
    Position the charging port assembly back into the body opening. Install and torque the four charging port mounting bolts to specification in a cross pattern. Reconnect the low-voltage signal connector until the locking tab clicks.
    Torque spec

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

    Reinstall charge port cover
    Position the charge port cover and install the cover screws. Torque to specification. Verify cover sits flush with body panel and charge port door operates smoothly through full range of motion.
    Torque spec

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

    Re-energize high-voltage system
    Reinstall all underbody panels removed for access. Reinstall the high-voltage service disconnect plug, ensuring it clicks fully into place. Reconnect the 12V auxiliary battery negative terminal. Reinstall wheel well liner and wheel if removed.

Reassembly

1. Verify all underbody panels are properly secured and no tools or parts are left in vehicle
2. Confirm charge port door operates smoothly and closes completely
3. Check that all cable routing maintains proper clearance from suspension, steering, and drivetrain components

Verification

• Turn vehicle to ON mode and verify no high-voltage system warning lights or messages appear on instrument cluster
• Connect a Level 2 charging cable to the charge port and verify vehicle recognizes connection (green indicator light on dash)
• Monitor charging for first 10 minutes to ensure proper operation and no error codes
• Verify charging rate matches expected Level 2 charging speed (typically 7.2 kW for Bolt EUV)
• Inspect all connection points for proper seating, no heat buildup, and no unusual odors
• Test charge port door release button functions properly from both inside vehicle and charge port area

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