[Sean Nelson]

Since all 2019 are the same and the replacement batteries too, it must be a difference in owner behavior that makes this happen more or less often.

It could just be tolerances, wear or grit that make the pin easier or harder to slide. And it's a bit of a moot point now that a software patch to fix the problem has been made available.

 

[kraftwerksoworkit]

recall:

https://www.chevrolet.com/ownercenter/recalls?vin=1G1FY6S01K4143644&evar36=eml_monthly_onstar_OVD&vels=1180947803

• Advanced Diagnostic Software (ADS) Improvements

• GM Program #:
• N222369400

• Date Issued:
• Aug 17, 2022

Program Title:
Advanced Diagnostic Software (ADS) Improvements
Program Description:
Certain 2017-2019 model year Chevrolet Bolt EV vehicles are to receive a software update to improve the original Advanced Diagnostic Software. This software update addresses customer reports of difficulty connecting to a charger (2019 MY only), reduces false diagnostic activation in certain vehicles under certain driving conditions, and prevents diagnostic data loss.

Repair Description:
Dealers are to reprogram the Hybrid Powertrain Control Module 2 (HPCM2).

 

[cwerdna]

Yes. We know. See GM Program #N222369400 Aug 17, 2022.

 

[Jeff Mann]

I cannot plug the charging cable into the charge port of my (post-recall-fix, 2019, LT DCFC) Bolt.

The problem is the metal "latch" at the top of the charger (see photos) is stuck in position, and physically blocks the top plastic prong on the charge cable. The charge cord cannot get far enough in to click into place. The latch itself seems to be locked in place by a metal prong coming in from the top left.

I think this is meant to be the mechanism that locks the charger in place when the car is charging, but now it is locking the charger out of the port.

I don't know what happened. One day it worked, the next day it didn't.

(I tried lots of different charging cables, and it's definitely a problem with the car's port not the charging cable. I only tried L2 chargers, but I assume no kind of charging cable would work. I turned it on and off a few times and nothing changed. I tried prodding it with a plastic stick and that didn't do anything.)

Ideas/suggestions?

View attachment 39784 View attachment 39785 View attachment 39786

Based on what has been said, the problem appears to be a software bug. Unplugging the 12 volt battery resets to computer. If there was an easier way to reset the computer, that would be better.

 

[Jeff Mann]

Based on what has been said, the problem appears to be a software bug. Unplugging the 12 volt battery resets to computer. If there was an easier way to reset the computer, that would be better.

I've been checking the prong and I can't find any conditions that make it go out or in. I don't even know why it's there. It appears to be an absolute random thing. Another programmer making peoples' lives miserable. If I can figure anything out, I will let you know.

 

[Greenfan]

I,ts function is to prevent the charge plug from being removed during fast charging to prevent arcing.

 

[PLP]

I've been checking the prong and I can't find any conditions that make it go out or in. I don't even know why it's there. It appears to be an absolute random thing. Another programmer making peoples' lives miserable. If I can figure anything out, I will let you know.

No, it is not random.
It is used only during DC charging.
If you ever charged using DC (50 kW vs 7.2 kW with "regular" 240 charger) you would know that it takes much longer for the EVSE to establish communication and start charging. The same happens when you want to finish the session. It takes several seconds to stop it.
Hence the pin to lock the handle.

When you are disconnecting the L2 charger, you depress the switch on the handle what stops the charging. It has enough time to disconnect and you pull it out.

 

[BCi]

Hi Boltemort,

Good and bad news... our 2019 pre-recall-fix is having the same issue. It seems to have started since the software update that limited charging for safety.

Bad news, no one seems to know anything about it or if there is a fix or if it is a hardware or software failure.
Good news, I have a workaround that works, but is rather a PITA.

You are right that the issue isn't the latch itself, but the locking pin behind the latch. The pin should lock the latch in place during charging to prevent inadvertent disconnects, but for some reason it decides randomly every couple of days to lock when there is nothing plugged in, thus preventing the cable from being fully seated.

We've tried every possible easy solution under the sun to get it to unlock, but we've found only one PITA solution that works... pulling the 12v, waiting a minute or two, and reconnecting it. Fixes it every time, and is a complete and total pain... good reason to make sure you have a 10mm in your car at all times.

Good luck!

JWH

THANKS. YOU ARE A LIFESAVER. I DISCONNECTED THE 12 VOLT BATTERY. WHEN I RECONNECTED IT FIVE MINUTES LATER, I HEARD A CLICK, THE LATCH HAD RESET TO THE PROPER POSITION AND I WAS ABLE TO CHARGE OUR 2019 BOLT. WE ARE TAKING IT TO THE CHEVY DEALER TOMORROW. DO YOU KNOW WHAT IS CAUSING THIS MALFUNCTION?

 

[MichBolt]

THANKS. YOU ARE A LIFESAVER. I DISCONNECTED THE 12 VOLT BATTERY. WHEN I RECONNECTED IT FIVE MINUTES LATER, I HEARD A CLICK, THE LATCH HAD RESET TO THE PROPER POSITION AND I WAS ABLE TO CHARGE OUR 2019 BOLT. WE ARE TAKING IT TO THE CHEVY DEALER TOMORROW. DO YOU KNOW WHAT IS CAUSING THIS MALFUNCTION?

See post #342 above yours in this same thread:

charging port will not accept charging cable

Since all 2019 are the same and the replacement batteries too, it must be a difference in owner behavior that makes this happen more or less often. It could just be tolerances, wear or grit that make the pin easier or harder to slide. And it's a bit of a moot point now that a software patch to...

www.chevybolt.org

 

[M. Neiberg]

We are having the same problem and the dealer wants to charge $150 to diagnose this known problem. I'd love to find a non-dealer service solution, since the dealer doesn't have a lot of experience with the Bolt in any event

 

[MichBolt]

We are having the same problem and the dealer wants to charge $150 to diagnose this known problem. I'd love to find a non-dealer service solution, since the dealer doesn't have a lot of experience with the Bolt in any event

Generally speaking, the dealership has to diagnose the problem independently of what the customer suggests is the cause of the problem. If the cause is covered under warranty, then the diagnosis should also be covered. If the cause is not under warranty, then the dealer is compensated for the diagnosis and you have to decide whether to repair.

 

[Birdguy_Idaho]

Mine started doing this either after the software update, or the battery replacement, I'm not sure.
Here's how I fixed mine: I disconnected the negative terminal, waited a few minutes, then closed the charge port door. I then reconnected the battery and heard the little servo engage. Opened the port door and 'Voila', it was reset!

 

[rlhammon]

I've tried reading most of the pages here... wondering if someone can answer this.

Is this issue experienced only by those who got the charge limiting software before they got the battery recall completed? I've never had this issue and my battery was replaced Nov. 2021 before the software was even available so I never had the limit applied or removed.

I see no reason to allow gm to update software that doesn't have the issue seeing as they have a history of screwing things up with each update.

 

[ARob]

I've tried reading most of the pages here... wondering if someone can answer this.

Is this issue experienced only by those who got the charge limiting software before they got the battery recall completed? I've never had this issue and my battery was replaced Nov. 2021 before the software was even available so I never had the limit applied or removed.

I see no reason to allow gm to update software that doesn't have the issue seeing as they have a history of screwing things up with each update.

After the battery replacement, GM pushes a diagnostic update. That appears to be where the problem arises...but a recent patch in the last month or so apparently fixes this condition. So going forward, this is less likely to be a problem.

 

[stangbat]

Is this issue experienced only by those who got the charge limiting software before they got the battery recall completed? I've never had this issue and my battery was replaced Nov. 2021 before the software was even available so I never had the limit applied or removed.

My car exhibits this issue. I had the first software update done (N202311731), but not the second one that limited the top charge to 80%. I didn't have any problems until after my battery was replaced and they updated the software at that time. So I don't know. Could be a weird combination of things.

Maybe you lucked out and your 2019 is early or late enough of a build that it isn't subject to this issue.

I'm actually taking my car in tomorrow morning for the fix that is supposed to take care of this.

 

[rlhammon]

After the battery replacement, GM pushes a diagnostic update. That appears to be where the problem arises...but a recent patch in the last month or so apparently fixes this condition. So going forward, this is less likely to be a problem.

There seems to be a lack of understanding as to which software caused this issue, but I haven't had the issue in nearly a year of L1, L2, or L3 charging since my battery replacement so I'm unlikely to go out of my way to accommodate a software update on a car that's supposed to capable of OTA updates.

 

[rlhammon]

My car exhibits this issue. I had the first software update done (N202311731), but not the second one that limited the top charge to 80%. I didn't have any problems until after my battery was replaced and they updated the software at that time. So I don't know. Could be a weird combination of things.

Maybe you lucked out and your 2019 is early or late enough of a build that it isn't subject to this issue.

I'm actually taking my car in tomorrow morning for the fix that is supposed to take care of this.

Sorry to hear you're having the issue. I didn't let gm limit my car at all, because I wouldn't have been able to make my daily commute in the winter. I fought hard to get my battery replacement, ultimately filing a complaint with my State Attorney General to force the issue since gm wouldn't do a buyback.

I'll toss a screwdriver and a 10mm socket in the car. That's far less a hassle than trying to get the car to a dealership, take a vacation day (because they have no courtesy vehicles), and dealing with the next recall. IMO the less gm touches the car the better it's going to be based on their track record with software fixes on the Bolt.

 

[stangbat]

I'll toss a screwdriver and a 10mm socket in the car. That's far less a hassle than trying to get the car to a dealership, take a vacation day (because they have no courtesy vehicles), and dealing with the next recall.

You'd have had the issue by now if your car was subject to it.

I keep a 10mm wrench in my car just in case the car needs to be reset, but I've never used it for the charging port issue. Every few weeks I use a small flat blade screwdriver and push the pin back into place. So I've never had to disconnect the battery due to the issue, but I'm tired of having to mess with it.

But yeah, I'm not looking forward to tomorrow. Hopefully they'll get me in and out quickly, should be a quick update if they get me in at the scheduled time. This will be my third trip to the dealer due to the battery issues.

 

[dborn]

I've tried reading most of the pages here... wondering if someone can answer this.

Is this issue experienced only by those who got the charge limiting software before they got the battery recall completed? I've never had this issue and my battery was replaced Nov. 2021 before the software was even available so I never had the limit applied or removed.

I see no reason to allow gm to update software that doesn't have the issue seeing as they have a history of screwing things up with each update.

I've had all of the updates done since the beginning. Had the battery replaced in March '22 and not once did I get any problem after that. After the latest recall done a few weeks ago, I swear the locking pin now looks slightly more recessed than before even if it never blocked using the charge handle. Hope this is the last battery related issue...

 

[Papa Smurf]

The latch is a safety feature to prevent pulling a 'hot' plug before shutting off tge power. The push button on the plug is supposed to signal the onboard charger and the evse (dcfc) to kill the juice, then it will release the latch. I guess you could cut off the hook, but you might arc your connection and damage it.