DC Fast Charge Port

This procedure covers the removal and replacement of the DC fast charge port assembly on a 2023 Chevrolet Bolt EUV, including high-voltage system de-energization and proper reconnection.

Warnings

Tools required

Parts

• DC Fast Charge Port Assembly × 1 — Use OEM specification
• Charge port seal/gasket × 1 — Usually included with port assembly
• High-voltage connector service lock × 1 — Use OEM specification if damaged

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure vehicle is NOT plugged into any charging source (AC or DC)
3. Turn off vehicle completely and remove key fob from interior
4. Open rear cargo area and locate high-voltage service disconnect under rear floor panel
5. Wear high-voltage insulated gloves rated for minimum 1000V
6. Remove 12V battery negative terminal and isolate cable
7. Wait minimum 5 minutes for high-voltage system capacitors to discharge

Procedure

1. 1

   Access charge port area
   Open the charge port door on the driver side front fender. Remove the charge port door assembly by releasing the hinge clips. Use plastic trim tools to carefully pry the inner fender liner away from the charge port area to gain access to the mounting hardware and connectors.
2. 2

   Remove charge port cover
   Locate and remove the protective cover over the charge port assembly. Remove the cover screws securing the assembly access panel. Carefully set aside the cover to avoid damage to sealing surfaces.
   Torque spec

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

   Verify high-voltage system de-energization
   Using a high-voltage capable multimeter, verify that no voltage is present at the DC fast charge port terminals. Measure between DC+ and DC- terminals, then between each terminal and vehicle ground. All readings must be 0V before proceeding. If voltage is detected, re-check service disconnect and wait additional time.
   ⚠️Do not proceed if any voltage is detected. System may not be fully de-energized.
4. 4

   Disconnect high-voltage cables
   Wearing high-voltage insulated gloves, locate the high-voltage connector bolts securing the orange cables to the DC fast charge port. Remove the connector locking mechanism. Remove the high-voltage connector bolts in sequence, then carefully pull the connectors straight out from the charge port terminals. Inspect connectors for damage, corrosion, or contamination.
   ⚠Do not twist or bend high-voltage cables excessively. Support cable weight to prevent strain on connectors.
   Torque spec

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

   Disconnect communication and sensor connectors
   Locate the low-voltage communication connector and temperature sensor connector on the charge port assembly. Press the locking tabs and carefully disconnect both connectors. If equipped with sensor bolts securing sensor to port assembly, remove them now.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
6. 6

   Remove mounting bracket bolts
   Locate the bracket bolts securing the charge port mounting bracket to the vehicle body structure. Remove all bracket bolts while supporting the charge port assembly to prevent it from falling.
   Torque spec

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

   Remove charge port assembly
   Remove the charging port mounting fasteners securing the port assembly to the vehicle body. Carefully extract the DC fast charge port assembly from the fender area, routing cables through the access opening. Inspect the mounting area and seal surfaces for damage or corrosion.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
8. 8

   Prepare new charge port
   Unpack the new DC fast charge port assembly and verify all components are present. Inspect the new port terminals for any shipping damage or contamination. Install new gasket/seal onto the port assembly. Apply a thin coat of dielectric grease to high-voltage terminal contact surfaces if not pre-applied.
9. 9

   Install new charge port assembly
   Route the new charge port assembly into the fender area, ensuring cables are properly positioned and not kinked. Align the port assembly with mounting holes and install charging port mounting fasteners. Torque fasteners to specification in a cross pattern to ensure even sealing.
   Torque spec

   Charging Port Mounting8 Nm (6 lb-ft)
10. 10

    Install mounting brackets
    Position the mounting bracket and install bracket bolts. Torque bracket bolts to specification, ensuring the charge port assembly is securely supported and properly aligned with the fender opening.
    Torque spec

    Bracket Bolts20 Nm (15 lb-ft)
11. 11

    Reconnect sensors and communication
    Reconnect the temperature sensor and communication connectors to the charge port assembly. Ensure locking tabs fully engage. If sensor bolts were removed, reinstall and torque to specification.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
12. 12

    Reconnect high-voltage cables
    Inspect high-voltage cable connectors for any damage or contamination. Clean terminals if necessary with appropriate contact cleaner. Align high-voltage connectors with charge port terminals and push straight in until fully seated. Install high-voltage connector bolts and torque to specification. Install connector locking mechanism.
    ⚠Ensure connectors are fully seated before installing bolts. Partial connection can cause arcing and damage.
    Torque spec

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

    Install protective cover
    Position the protective cover over the charge port assembly and install cover screws. Torque to specification. Reinstall inner fender liner and secure all clips.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
14. 14

    Re-energize high-voltage system
    Reconnect 12V battery negative terminal. Reinstall high-voltage service disconnect in rear cargo area. Close all panels and covers. Turn vehicle to ON position and verify no high-voltage system warning lights are illuminated on instrument cluster.

Reassembly

1. Reinstall charge port door assembly and verify smooth operation
2. Ensure all fender liner clips are fully engaged and no gaps are present
3. Verify charge port door closes flush with body panel

Verification

• Connect vehicle to a DC fast charger and verify successful charging handshake and charge initiation
• Monitor charging for first 5 minutes to ensure no error messages or interruptions occur
• Verify charge port temperature sensor is reading properly in vehicle diagnostics
• Check for any warning lights related to charging system on instrument cluster
• Perform visual inspection of charge port area for proper sealing and alignment
• Test charge port door operation for smooth opening and closing

Related trouble codes on this vehicle

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

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle