Chevrolet
Thermal Damage / Overheating of Components
Burning smell or visible discoloration around the charger or cable during or after charging.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Loose high-current connections, Damaged or undersized cable, Internal contactor failure, Prolonged operation above rated current
How to Fix / Troubleshooting
Safety first: Immediately turn OFF the breaker and do not use the charger until inspected. Fire risk is present.
- Step 1 – Visual inspection: After cooling, inspect the charger enclosure, cable entry, and J1772 handle for melted plastic, discoloration, or soot.
- Step 2 – Check terminals: With power OFF, open the charger and inspect all high-current terminals for signs of arcing or looseness.
- Step 3 – Replace damaged parts: Any melted connector, cable, or terminal block must be replaced. Do not attempt to reuse overheated components.
- Step 4 – Verify current setting: Ensure the charger’s maximum current does not exceed the rating of the branch circuit and the charger model.
- Step 5 – Professional evaluation: Have an EVSE technician evaluate the contactor and control board for hidden damage.
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Repair Difficulty
Professional Required
5/5
Required Part
Chevrolet J1772 Charge Cable and Handle Assembly
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