Chevrolet Arcing at EV Connector

Visible arcing or sparking when plugging or unplugging the J1772 connector from the vehicle.

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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

Disconnecting under load due to stuck contactor, Worn or pitted connector pins, Loose fit between J1772 handle and vehicle inlet, Contaminants on contacts increasing resistance

How to Fix / Troubleshooting

Safety first: Stop using the charger immediately if you see sparks or hear loud popping. Turn OFF the breaker before inspecting.

  • Step 1 – Inspect connector pins: Look for blackened, pitted, or deformed pins in the Chevrolet J1772 handle. Do not continue using a damaged connector.
  • Step 2 – Check vehicle inlet: Inspect the vehicle’s charge port for similar damage or debris.
  • Step 3 – Clean contacts: If only light discoloration is present, clean gently with a contact-safe cleaner and a non-metallic brush.
  • Step 4 – Verify proper sequence: Ensure that the charger is not energizing the connector before it is fully inserted. If arcing occurs even with normal use, the contactor timing or control board may be faulty.
  • Step 5 – Replace damaged parts: Replace the J1772 cable/handle assembly and, if necessary, have the vehicle inlet inspected by a dealer.
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Repair Difficulty

Medium 3/5

Required Part

Chevrolet J1772 Charge Cable and Handle Assembly
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