LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2011 >> Volt >> Repair and Diagnosis >> Electrical >> Charging Systems >> Plug-In Charging >> Repair Instructions >> Charge Port Door Actuator Cable Replacement
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Charge Port Door Actuator Cable Replacement

Fig 1: Charge Port Door Actuator Cable
GM2392709Courtesy of GENERAL MOTORS CORP.
Callout Component Name
WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
  • Identify how to disable high voltage.
  • Identify how to test for the presence of high voltage.
  • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
  • Safety glasses with appropriate side shields when within 50 feet of the vehicle, either indoors or outdoors.
  • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
    • Visually and functionally inspect the gloves before use.
    • Wear the Insulation gloves at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures exactly as written may result in serious injury or death.
WARNING: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.

Preliminary Procedures

  1. Disable the high voltage system. Refer to High Voltage Disabling .
  2. Remove the left front wheelhouse rear liner. Refer to Front Wheelhouse Rear Liner Replacement .
  3. Remove the charge port housing bezel. Refer to Charge Port Housing Bezel Replacement .
  4. Remove the charge port door actuator seal. Refer to Charge Port Door Actuator Seal Replacement .
  5. Using a 10 mm closed end wrench, turn the cable nut at the charge port housing 1/8 turn counter-clockwise to disengage the actuator cable lock from the charge port housing.
  6. Attach a string to the actuator end of the cable before removing the cable from inside of the fender.
  7. Pull the cable downward, outward from the charge port housing.
1 Charge Port Door Actuator Cable

Procedure

  1. Attach the string to the actuator end of the cable.
  2. Insert the actuator end of the actuator cable into the hole in the charge port housing assembly.
  3. Feed the cable in behind the fender in between the charge port receptacle cable and inner fender to the top of the charge port door actuator assembly using the string as a guide.
  4. Using the 10 mm closed end wrench, align the tabs on the nut end of the cable to the slots in the housing.
  5. Hold the cable in position and turn the nut 1/8 turn clockwise to lock the cable to the charge port housing.
  6. Remove the string from the actuator end of the cable.
  7. Install the charge port door actuator seal. Refer to Charge Port Door Actuator Seal Replacement .
  8. Enable the high voltage system. Refer to High Voltage Enabling .
scientia non olet · About LEMON Manuals