Onboard Charger R&R

This procedure covers the removal and replacement of the onboard charger module in a 2023 Chevrolet Bolt EUV, including high-voltage system de-energization and component access.

Warnings

Tools required

Parts

• Onboard charger module × 1 — Use OEM specification
• High-voltage connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle has been off for at least 30 minutes to allow components to cool
3. Verify you have high-voltage safety training and appropriate PPE
4. Disconnect the 12V battery negative terminal and wait 2 minutes
5. Ensure work area is dry and free of conductive materials
6. Review vehicle service manual for high-voltage system layout

Procedure

1. 1

   Remove rear cargo area trim panels
   Open the rear liftgate. Remove the rear cargo floor cover and side trim panels on the driver's side to access the onboard charger location. The charger is mounted on the left side of the rear cargo area behind the trim. Remove any cargo hooks or fasteners securing the trim panels.
2. 2

   Access high-voltage service disconnect
   Locate the high-voltage service disconnect in the rear cargo area under the load floor. Remove the protective cover by loosening the cover screws. The disconnect is typically marked with a high-voltage warning label.
   Torque spec

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

   De-energize high-voltage system
   Wearing high-voltage gloves, grasp the high-voltage service disconnect handle and rotate counterclockwise, then pull straight out to remove. Store the disconnect in a secure location away from the vehicle. Wait minimum 10 minutes for high-voltage capacitors to discharge. Install lockout/tagout device if available.
   ⚠️Do not proceed until 10 minutes have elapsed after removing service disconnect.
4. 4

   Verify zero voltage
   Using a high-voltage capable multimeter, verify zero voltage across the high-voltage bus terminals. Measure at the service disconnect connector. Voltage must read below 3V DC before proceeding. Document the reading if required by shop procedures.
   ⚠️If voltage is present, do not proceed. Investigate cause of residual voltage.
5. 5

   Disconnect charging port connections
   Locate the AC input cable from the charging port to the onboard charger. Press the connector release tab and disconnect the AC input connector from the charger inlet. Note the routing of the cable for reinstallation. Tag or photograph wire positions if needed.
6. 6

   Remove high-voltage DC output connectors
   Wearing high-voltage gloves, locate the DC output connectors (orange cables) on the onboard charger output side. Remove the high-voltage connector bolts securing each connector. Carefully pull the connectors straight off the charger terminals. Cover exposed terminals with insulating caps or tape.
   ⚠️Ensure high-voltage gloves are worn and voltage has been verified as zero before touching orange cables.
   Torque spec

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

   Disconnect communication and sensor connectors
   Locate the low-voltage communication harness connectors on the onboard charger. Press the connector lock tabs and disconnect all low-voltage connectors. These typically include CAN bus communication and temperature sensors. Remove sensor bolts if sensors are integrated into the charger.
   Torque spec

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

   Disconnect coolant lines (if equipped)
   The onboard charger may have coolant lines for thermal management. Place shop towels below connections. Loosen coolant line connector bolts and carefully disconnect lines. Be prepared for minor coolant spillage (typically less than 4 oz). Cap or plug lines and charger ports immediately to prevent contamination.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
9. 9

   Remove charger mounting bracket bolts
   Support the onboard charger with one hand or have an assistant hold it. Remove the bracket bolts securing the charger mounting brackets to the vehicle structure. Keep track of all mounting hardware, brackets, and spacers for reinstallation.
   Torque spec

   Bracket Bolts20 Nm (15 lb-ft)
10. 10

    Remove main charger mounting bolts
    Remove the main mounting bolts securing the onboard charger to its mounting location. Support the charger weight as you remove the final bolts. The charger weighs approximately 30 lbs, so use proper lifting technique.
    ⚠Charger is heavy and awkwardly shaped. Use assistance or proper lifting technique to avoid injury.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Remove onboard charger from vehicle
    Carefully maneuver the onboard charger out of its mounting location, ensuring no connectors or brackets are still attached. Watch for sharp edges on vehicle structure. Inspect the mounting area for any debris or damage. Place the old charger on a clean work surface.
12. 12

    Inspect and prepare new charger
    Inspect the new onboard charger for any shipping damage. Verify part number matches vehicle application. Inspect all high-voltage terminals for damage or contamination. Check that all mounting brackets transfer from old unit if not included with new charger. Inspect coolant ports and connectors for damage.
13. 13

    Install new onboard charger
    Position the new onboard charger into the mounting location, aligning mounting holes with vehicle structure. Install main mounting bolts and tighten to specification. Ensure charger is properly seated and aligned before final torquing. Install bracket bolts and tighten to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

    Bracket Bolts20 Nm (15 lb-ft)
14. 14

    Reconnect coolant lines and low-voltage connectors
    Reconnect coolant lines if equipped, ensuring proper seating and tightening connector bolts to specification. Reconnect all low-voltage communication harness connectors, ensuring positive lock engagement. Install any temperature sensors and tighten sensor bolts to specification.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)

    Sensor Bolts11 Nm (8 lb-ft)
15. 15

    Reconnect high-voltage DC connectors
    Wearing high-voltage gloves, remove insulating covers from terminals. Inspect high-voltage connector seals and replace if damaged. Carefully align DC output connectors (orange cables) with charger terminals and press firmly until seated. Install high-voltage connector bolts and tighten to specification. Ensure proper torque is critical for electrical connection integrity.
    ⚠Proper torque on high-voltage connectors is critical to prevent arcing and overheating. Use calibrated torque wrench.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
16. 16

    Reconnect AC input from charging port
    Reconnect the AC input cable from the charging port to the onboard charger inlet. Ensure connector is fully seated and lock tab engages. Route cable according to original path, securing with cable ties if necessary. Verify no pinch points or interference with moving components.
17. 17

    Reinstall high-voltage service disconnect
    Remove lockout/tagout device if installed. Align the high-voltage service disconnect with its receptacle and push straight in until fully seated. Rotate clockwise to lock in position. Install protective cover and tighten cover screws to specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
18. 18

    Reconnect 12V battery and clear codes
    Reconnect the 12V battery negative terminal. Using a diagnostic scan tool, clear any high-voltage system DTCs that were set during the procedure. Check for any new fault codes that may indicate installation issues.

Reassembly

1. Reinstall all rear cargo area trim panels and fasteners in reverse order of removal
2. Ensure all trim panels are properly seated and secured
3. Reinstall cargo floor cover and any removed cargo hooks or accessories
4. Verify coolant level is correct if coolant lines were disconnected (add ACDelco DEX-COOL if needed)

Verification

• Turn vehicle to ON position and verify no high-voltage system warning lights remain illuminated
• Using scan tool, verify onboard charger communication is established and no DTCs are present
• Plug in a Level 1 or Level 2 charging cable and verify charging initiates normally
• Monitor charging for at least 5 minutes to verify proper operation and no fault codes
• Check for any unusual noises, smells, or warning messages during charging
• Verify charging rate is within normal parameters for the connected charging level
• Inspect all connection points for proper seating and no signs of overheating after initial charging test

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