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Discussion Starter #1 (Edited)
Hey Guys
I’ve seen many pics and posts about poor charge door alignment. I just got a beautiful 2017 CPO Volt and one thing I noticed right away (even in pictures) was the bad fit of the charge door.
I’ve seen other posts where someone's fix was to use a heat gun to deform the plastic door hinge!
I knew there had to be a reason it didn't fit right, and a better solution. Believe I found it.
The charge door and frame is a one piece assembly that just pops out of the fender.
Along the bottom of the housing frame is a small wiring harness. It is supposed to be secured in place by plastic guides, but a section of the harness was in fact pinched between the door housing and quarter panel. That caused the whole door assembly to not snap into the fender as far as it should and cause the door to not fit right when closed.
Simple fix. Remove housing, re route wire harness into guide tabs and snap back in. In the second pic you can see where the harness was pinched flat.
Hope this helps someone else. Another assembly line error overcome:)
 

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Isn't that harness for the illuminated port ring only? Might not cure the misalignment for the non illuminated ports. Tell us more about how the port housing pops out. What kind and where are the retainers?
 

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Discussion Starter #3 (Edited)
Isn't that harness for the illuminated port ring only? Might not cure the misalignment for the non illuminated ports. Tell us more about how the port housing pops out. What kind and where are the retainers?

I don't have the illumination ring. The wire is for the door position sensor. Gently pry the rear of the housing outward, it just pivots out & around forward from there. Look underneath and there's the wire.
 

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Discussion Starter #5
Ah, great. Mine is only slightly crookedy. I'll check it out this weekend. Thanks.
BTW, the body-color painted door panel slides off the door hinge easily. Open the door, and there is a black tab, one the back of the door in the middle. use a small flat head screwdriver to pry the tab out and slide the painted door off. Gives you more room to work with housing and not damage the door panel.
 

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Door cover slipped off as described, but was unable to pry the panel out, gently or otherwise. After some scary popping sounds I managed to force it out maybe 1/4" at the rear with no progress toward the front so I gave up. This is a 2018; wonder if things changed from '17.
 

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OP, glad to hear there is a potentially simple solution.

What was your alignment issue? Was the door higher or lower than the fender, and at which end?

My charge port door is flush at the front, but about 1/8" inset at the rear. I have the illuminated charge port, so I'm afraid it's going to be a chore to get the housing off.
 
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