Charge Port Door Replacement

Fig 1: Charge Port Door

Courtesy 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 Electrically release and open the charge port door. Disable the high voltage system. Refer to High Voltage Disabling .
1	Charge Port Door Seal Procedure: Hold the charge port door with one hand and pull the seal from the inside of the door hinge in order to remove.
2	Charge Port Door Procedure Using a flat-bladed driver, lift slightly upward on the tab at the center of the hinge in order to release the door from the hinge assembly. Slide the door outward, away from the hinge and remove. Enable the high voltage system. Refer to High Voltage Enabling .

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

Electrically release and open the charge port door.
Disable the high voltage system. Refer to High Voltage Disabling .

Charge Port Door Seal
Procedure:
Hold the charge port door with one hand and pull the seal from the inside of the door hinge in order to remove.

Charge Port Door

Procedure

Using a flat-bladed driver, lift slightly upward on the tab at the center of the hinge in order to release the door from the hinge assembly.
Slide the door outward, away from the hinge and remove.
Enable the high voltage system. Refer to High Voltage Enabling .