GM Volt Forum banner

2011 Volt Charger Repaired with Pics

5100 Views 31 Replies 16 Participants Last post by  uchual
Ok guys, got a charger that was overheating the plug (wall to charger). Couldn't find any writeups on this except for the newer ones that actually have a cover that can be removed.

I had to pry off one side of the covers that act as way to keep your cord wrapped in place, then I had to dremel cut one side open. These are sealed and no other way to open it.

You can see the insulation flaking off the wires and is a definite fire hazard. I bought a heavy duty plug and has some spare pool light wiring which I believe is 14 guage. I used black plastic epoxy to seal it all back up. No easy task but she's back in operation and again and is now using the proper gauge wiring and no longer a fire hazard.

Electronics Electrical wiring Technology Electronic device Wire
Electronics Cable Technology Electronic device Wire
Wire Electrical wiring Cable Technology Auto part
View attachment 154533 Vehicle door Automotive mirror Rear-view mirror Vehicle Auto part
See less See more
1 - 5 of 32 Posts
Not real sure on the gauge, but was bigger than the stock wire. Either way, no more hot wires.

Not sure what a 12 or 8 amp your speaking of.
Reiterate: WOW! That is pretty scary. Was that the original OEM charger or an aftermarket? When overheating starts it sometimes introduces more resistance with oxided wires which makes it overheat more in an increasing cycle (not usually a problem with soldered multistrand though). Almost as if the insulation was subpar re its temperature resistance with further exacerbated the problem.
Yes, you can see it was an OEM Voltec charger.
I called the local dealer as I read that all these 2011 and 2012 charger would be replaced for free, but they said there was no recall, blah blah. Knowing I was going to get the run around, I proceeded to remedy the issue myself.
The charge current on the OEM EVSE for 2011 is set on the EVSE not in the car. Selection is done by pressing a mechanical button on the EVSE which stays in the selected mode until it is pressed again to change the current setting.

VIN # B0985
Interesting. Didn't know that. I have it charging my Volt right now at it's default level with no issue on the cord heating up like it did before.
1 - 5 of 32 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.