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Charge Port Housing Replacement

Fig 1: Charge Port Housing
GM2392704Courtesy 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. Disengage the cable end from the charge port door actuator.
  4. Using needle nose pliers, pinch the back of the retainer tabs to disengage the charge port door actuator harness retainer from the edge of the fender.
  5. Disconnect the electrical connector for the charge port door ajar indicator switch assembly.
  6. Remove the charge port door. Refer to Charge Port Door Replacement .
  7. Remove the charge port housing bezel. Refer to Charge Port Housing Bezel Replacement .
1 Charge Port Housing Assembly
CAUTION: Refer to Exterior Trim Emblem Removal Caution .

Procedure

  1. From inside the fender, release the lower tab to the charge port housing assembly.
  2. Push outward on the assembly housing.
  3. Using a plastic trim-type stick, at the arrows, gently pry outward while pulling outward on the rear edge of the housing.
  4. Rotate the rear edge of the housing forward, pull the housing and seal from the front fender center reinforcement bracket.
  5. Remove the charge port housing assembly along with the electrical harness for the charge port door ajar indicator switch assembly and charge port door actuator cable assembly.
  6. Transfer the charge port door ajar indicator switch assembly. Refer to Charge Port Door Ajar Indicator Switch Replacement .
  7. Transfer the charge port door actuator cable. Refer to Charge Port Door Actuator Cable Replacement .

    Tip: 

    Upon the final assembly of the charge port housing into the front fender center reinforcement bracket, ensure to re-seat the charge port housing seal around the entire circumference of the charge port receptacle. Use a blunt tool such as a rounded plastic trim tool to push the seal into position around the charge port receptacle.

  8. Enable the high voltage system. Refer to High Voltage Enabling .
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