[nismoRB]

So today some asshole yanked the charger from my volt and broke my charge port. The plastic housing completely broke off and bent all the pins. I was able to bend the pins back and can continue to charge but I want to get this fixed. Does anyone know how to replace the plastic housing/port? I removed the silver bezel but there are no visible screws.

 

[Upper5Percent]

Is this what broke?
https://parts.ganleygm.com/p/Chevro...--2011-13-Housing-assy/54021408/22847243.html

 

[Mister Dave]

Possibly helpful photo.

You don't say what year. Here's the procedure for a 2012:

Danger: 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 conditions 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 goggles with appropriate side shields when within 15 metres (50 feet) of the vehicle, either indoors or outdoors.
• Certified and up-to-date Class "0" Insulation gloves rated at 1000 V with leather protectors.
- Visually and functionally inspect the gloves before use.
- Wear the Insulation gloves with leather protectors at all times when working with the high-voltage battery assembly, whether the system is energised or not.
Failure to follow the procedures exactly as written may result in serious injury or death.
Danger: The Volt Battery Pack will utilise 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 Centre (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 .

Procedure
1. From inside the wing, release the lower tab to the charge port housing assembly.
2. Push outwards on the assembly housing.
3. Using a plastic trim-type stick, at the arrows, gently pry outwards while pulling outwards on the rear edge of the housing.
4. Rotate the rear edge of the housing forwards, pull the housing and seal from the front wing centre 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 wing centre 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 .



Or you can take it to the dealer.

 

[Steverino]

Pictures of the broken area would be helpful.

I'm always amazed when problems are posted without identifying the year of the car. One of the first things a repair shop will ask is , "What year is the car?"

 

[mpmoore1979]

You have to remove the charge port door assembly to get to the bolts and the charge port. The door is not held in with screws, you have to pry it out from around the fender. You should be able to lift the rubber around the fender area and see the retainer tabs that hold the door on. This is kind of tricky but the hardest part of the job. When you get the door off, you will see the 4 bolts that hold the port on to the car, they have tread locker on the bolts so coming off with the bolts can be hard. When you get the bolts off, just unplug the port and replace. you do not need to remove the fender wheel well liner or the tire. You may break one of the bolts, thats OK. The charge port will hold in place with 3, just be careful.

 

[fotomoto1]

I predicted this scenario as wells as EVSE cord theft years ago. Really sad to see both happening. Fortunately I haven't read of an example of my third prediction happening; that of bad people, beggars, low life types etc. targeting charging locations/folks waiting on a QC session.

 

[scottf200]

So today some asshole yanked the charger from my volt and broke my charge port. The plastic housing completely broke off and bent all the pins. I was able to bend the pins back and can continue to charge but I want to get this fixed. Does anyone know how to replace the plastic housing/port? I removed the silver bezel but there are no visible screws.

Steverino did point me to this picture in a thread I had a little while ago.
http://gm-volt.com/forum/showthread...charging-but-it-is-not.&p=4288489#post4288489

 

[nismoRB]

Possibly helpful photo.

Exactly what I needed! Thank You!

 

[nismoRB]

Pictures of the broken area would be helpful.

I'm always amazed when problems are posted without identifying the year of the car. One of the first things a repair shop will ask is , "What year is the car?"

Well I asked my question in the 1st gen forum, are there differences in the charge port between 2011-2015?

 

[nismoRB]

I predicted this scenario as wells as EVSE cord theft years ago. Really sad to see both happening. Fortunately I haven't read of an example of my third prediction happening; that of bad people, beggars, low life types etc. targeting charging locations/folks waiting on a QC session.

Unfortunately it was another asshole with an electric vehicle. GF took my car to work at the local community college and plugged in at a public charging station in the parking lot. When she came back at lunch to disconnect someone had ripped the charger out without depressing the release tab breaking the housing off. It seems the students/faculty have no charging etiquette there and just yank it from whoever is currently charging because the Volt was barely even charged. I told her not to charge there anymore.

 

[BAZINGA]

One of my biggest fears as well, some azzhole breaking it off just to make a political statement.

 

[emg77]

You might consult your insurance too. It would be a comprehensive claim which typically has a lower deductible and typically won't raise your rates. If the replacement parts cost more than your deductible, it might be worth filing a claim and just letting the dealership do the work.

If you do the repair yourself, if you need any parts, you could check www.car-part.com. I don't know if they will list the charge equipment, but you can at least see which yards have volts and you could call about getting that specific part from a totaled Volt.

Sorry this happened... that sucks.

 

[Mister Dave]

Exactly what I needed! Thank You!

You're welcome.

One of my biggest fears as well, some azzhole breaking it off just to make a political statement.

I watched a drunk walk into a side mirror and break it off of a car in the loading zone at the grocery store a few months back. He just kept going as if nothing happened. His statement wasn't political, it was "I'm drunk".

I didn't get the impression nismoRB thought it was a political statement either. Perhaps you're projecting.

 

[mpmoore1979]

Do not get a used part, the original part has issues with cracking and causing issues when charging. Get a new GM part that has been updated. All of GM stock will have the new updated part.

 

[Coppersnowboarder]

For a couple of years, I used a bike cable to lock my charging cable to the tire hub of my 2013 Volt. Then, I lost the key on vacation. I borrowed a hack saw and cut through the cable in ten minutes. There is no ideal deterrent for vandalism and theft. I have also had a charging cable removed at a charging station by the owner of an all-electric vehicle. I was recently hit by a welding truck at an intersection. The driver convinced the state patrol officer that he was stopped when I hit him. Face the fact that there are more bad people in our society than mis-behaved bears in the forest.

 

[Steverino]

Well I asked my question in the 1st gen forum, are there differences in the charge port between 2011-2015?

It's a general statement. You are asking for help, so take an extra second and supply some basic info. It's common courtesy so other don't need to guess what year. Depending on the car year, even within Gen 1, the answers can change based on the year and question. Plus people sometimes mistakenly post in the wrong forum.

 

[Upper5Percent]

For a couple of years, I used a bike cable to lock my charging cable to the tire hub of my 2013 Volt. Then, I lost the key on vacation. I borrowed a hack saw and cut through the cable in ten minutes. There is no ideal deterrent for vandalism and theft. I have also had a charging cable removed at a charging station by the owner of an all-electric vehicle. I was recently hit by a welding truck at an intersection. The driver convinced the state patrol officer that he was stopped when I hit him. Face the fact that there are more bad people in our society than mis-behaved bears in the forest.

Well, of course you showed the officer your dashcam footage to prove the other driver was lying...

 

[TripleTrucker]

Thought about this before. Seems there would be a design that would be more of a right angle for the charging plug.
The way it sticks out, it's almost begging for someone who is oblivious for just a jerk to damage it by just walking too close.

 

[Mister Dave]

Depending on the car year, even within Gen 1, the answers can change based on the year and question.

Very true. Parts of the procedure for 2012 don't apply to my Volt.

 

[wizard_of-ahs]

For a couple of years, I used a bike cable to lock my charging cable to the tire hub of my 2013 Volt. Then, I lost the key on vacation. I borrowed a hack saw and cut through the cable in ten minutes. There is no ideal deterrent for vandalism and theft. I have also had a charging cable removed at a charging station by the owner of an all-electric vehicle. I was recently hit by a welding truck at an intersection. The driver convinced the state patrol officer that he was stopped when I hit him. Face the fact that there are more bad people in our society than mis-behaved bears in the forest.

Hence the dashcam

Well, of course you showed the officer your dashcam footage to prove the other driver was lying...