Document ID: 3963140

2018 Chevrolet Volt | Volt Accessory Installation Manual | Accessories | Electrical Accessories | Accessories |
Document ID: 3963140

Charge Port Housing Package Installation (Instruction ID:

23413653)
Table 1: P/N 84334825 Kit Contents
Table 2: P/N 23413649 Kit Contents

Installation Instructions Part Number

23413653

Note: This installation instruction sheet can be used for either of 2 interchangeable Volt Illuminated
Charge Port kits, 84334825 and 23413649. Routing Aid Wire is no longer needed for installation
of either kit.

P/N 84334825 Kit Contents

QTY. P/N Description

1 84232971 Bezel Assembly

1 23413653 Instruction – Illuminated Bezel Assembly Install

1 84334824 Harness PKG – ACSRY WRG – Includes Tie Straps

P/N 23413649 Kit Contents

QTY. P/N Description

1 23413652 Bezel Assembly

1 23413653 Instruction – Illuminated Bezel Assembly Install

1 23446773 Harness PKG – ACSRY WRG – Includes Conduit and Tie Straps

Special Tools Required

Vinyl Tape (19mm)

Electrical connector terminal pick

Plastic Wedge Trim Tool

Note: Routing Aid Wire is no longer needed for installation of this Accessory.

Procedure

Note:

1. Read all instructions before performing procedure.

2. Inspect KIT to verify all parts
© 2017 are
General included.
Motors. All rights reserved.

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3. Turn OFF the vehicle.

4. Disconnect the 12 Volt battery. Refer to Vehicle Service Manual.
1. Remove the left front wheel and tire assembly. Refer to Vehicle Service Manual.

2. Remove the fasteners (1) holding the rear half of the left front wheel house liner (2).
3. Position the wheel house liner enough to view and access the rear of the charge port.

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4. Open the charge port door.

5. Open the hood.
6. Remove the charge port housing bezel (A).

7. Move left side hood rear outer seal (B) out of the way to provide visibility when routing the
accessory wire harness.

8. Stagger terminals on Bezel Assembly Pigtail (C) and route through drain hole one at a time,
(D) approximately 50.0 mm taking care not to damage terminals.

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9. Through the wheel well access the wire harness as it exits the drain hole (D), pull the harness
(C) fully through the drain hole.

Note: For P/N 23413649 kit includes a separate piece of plastic tubing (conduit); install the
conduit before continuing to step 11.

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10. Continue to pull the wire harness until it is visible between quarter panel outer and upper rail.
11. Assure bezel pigtail has been routed through drain hole (D) and there is no slack, but with no
strain on the accessory housing at the wire exit point.
Note: Ensure that the production charge port housing rear shroud is seated behind the
receptacle so that the shroud cannot interfere with the seating of the charge station
coupler. Use the Plastic Wedge Trim Tool to adjust the shroud as needed.

12. Seat bezel assembly into charge port housing by aligning the three bezel posts to housing
snap feature.
Note: Do not remove secured tape on back of housing.
Note: Install the illuminated bezel carefully. Do not pinch wire when installing, tuck wires out
of the way of snap posts before seating.

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13. Route bezel pigtail (C) as shown.

⇒ Check the Rear of the Engine Side Connector
Note: There are 3 possible installation methods, please determine the correct method to
use by following the flow chart below.

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Note: Check if the unused cavities are sealed using individual plugs or blocked by connector
body material (Flash).
14. Determine Wire Harness Version
⇒ A Early MY 16 Cavity Plug in Cavity 7

15. Disconnect main body harness (1) to engine harness (2) inline connection.
Note: Service Molex MX 150 service connector per GM service guidelines.
16. Disengage but do not fully remove TPA on the Engine Side Connector.
17. Using the terminal pick disengage finger lock and remove cavity plugs from cavities 7&8.

Note: Verify correct terminal orientation prior to inserting terminal.

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18. With the TPA still in the pre-lock position, insert the smaller terminal (Black Wire circuit 2750)
(1) for Cavity 7 to the rear of the connector (2).
19. Repeat for white wire (Circuit 9000) and Cavity 8
20. Re-engage TPA.
21. Reconnect Engine to Body Inline. Go to Step 38.
⇒ B Late MY 16, Early MY 17 / No Plug in Cavity 7 / Circuit in Bodyside Cavity 7

22. Disconnect main body harness (1) to engine harness (2) inline connection.
Note: Service Molex MX 150 service connector per GM service guidelines.
23. Disengage but do NOT fully remove the TPA on the Engine Side Connection.
24. Using the terminal pick disengage fingerlock and remove cavity plugs from cavities 8&11.

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25. On the body side connector remove and retain cavity plug from cavity 11.
26. Using the terminal pick remove the terminal from cavity 7 and insert in cavity 11. Insert
retained cavity plug in cavity 7.

Note: Verify correct terminal orientation prior to inserting terminal.

27. “Returning to the Engine Side” With the TPA still in the pre-lock position, insert the smaller
terminal (Black Wire circuit 2750) (1) for Cavity 11 to the rear of the connector (2).
28. Repeat for White Wire (Circuit 9000) and Cavity 8.
29. Re-engage TPA.
30. Reconnect Engine to Body Inline, re-attach inline to mounting bracket. Go to Step 38.
⇒ C Late MY 17 and Beyond / No Cavity Plug in Cavity 7 / Circuit in Bodyside Cavity 11

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31. Disconnect main body harness (1) to engine harness (2) inline connection.
Note: Service Molex MX 150 service connector per GM service guidelines.
32. Disengage but do NOT fully remove TPA on Engine Side Connector.
33. Using the terminal pick disengage the fingerlock and remove the cavity plugs from cavities
8&11.

Note: Verify correct terminal orientation prior to inserting terminal.

34. With the TPA still in the pre-lock position, insert the smaller terminal (Black Wire circuit 2750)
(1) for Cavity 11 to the rear of the connector (2).
35. Repeat for White Wire (Circuit 9000) and Cavity 8.

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36. Re-engage TPA.

37. Reconnect Engine to Body Inline. Go to Step 38.
⇒ Finish Installation and Test

38. Attach bezel pigtail (C) to main body harness (1) using tie straps from harness package
approximately 250.0 MM between each tie strap.

39. Reinstall left side hood rear seal (B)

40. Test the system to ensure it is installed properly:
40.1. Reconnect the 12 volt battery.
40.2. Turn on the vehicle.

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40.3. With the vehicle “ON”, open the charge port door. The illuminated bezel will turn on for
60 seconds.
41. The illuminated charge port will function as follows when a charge cord is attached:
The light stays on for 6 seconds while the system initializes and then will begin to flash
to indicate charge status.
Initial – Light On
0-25% – 1 Blink
25-50% – 2 Blinks
50-75% – 3 Blinks
75-100% – 4 Blinks
100% – Light Off after 60 seconds of unblinking illumination
When the charge cord is unplugged after a complete, or partial charge event, the light
will turn on for 60 seconds.
Note: The dashboard charge state lamp and the charge port light work identically as
above EXCEPT for the full charge state, the dashboard lamp remains illuminated
and unblinking even after the 60 second time out by door lamp.
42. Charge Port / Charge Station Coupler Test – Required to ensure that the vehicle charges
properly after the accessory installation.
42.1. Insert the charge station coupler into the vehicle charge port. Listen for a click
indicating coupler is fully seated.
42.2. Verify full insertion of the charge station coupler by pulling lightly on coupler. Ensure
charge station coupler cannot be removed without disengaging the latch on the coupler.
42.3. Check that the vehicle is charging and that the charge port light is indicating the state of
charge as described above.
42.4. Check accessory bezel to assure proper seating adjustment as necessary.

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Caution: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or
fasteners requiring the use of thread locking compound or sealant are identified in
the service procedure. Do not use paints, lubricants, or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings affect fastener
torque and joint clamping force and may damage the fastener. Use the correct
tightening sequence and specifications when installing fasteners in order to avoid
damage to parts and systems.
43. Reposition the wheel house liner and install the fasteners (1) holding the rear half of the left
front wheel house liner (2).
Tighten
Tighten the wheel house liner fasteners to 2.5 N.m (22 lb in).
44. Reinstall the left front wheel and tire assembly. Refer to Vehicle Service Manual.

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