EV SYSTEMS

24-EV-002G

MARCH 2024

GV60 Electric (JW1 EV)
G80 Electrified (RG3 EV)
GV70 Electrified (JK1a EV)

INSPECTION/REPLACEMENT OF EV CHARGING PORT INSULATION CAP
Description: If you are servicing a vehicle with a missing or damaged insulation cap from the EV
Charging Port follow the information in this TSB to replace any missing/damaged insulation cap(s) on
certain 2023-24MY GV60 (JW1 EV), G80 Electrified (RG3 EV) and GV70 Electrified (JK1a EV) vehicles.
The charging insulation caps are important to ensure proper charger connector orientation and fit to the
vehicle charge port.
Applicable Vehicles:
• 2023-24MY GV60 (JW1 EV)
• 2023-24MY G80 Electrified (RG3 EV)
• 2023-24MY GV70 Electrified (JK1a EV)
Parts Information:
Model

Spec.

GV60
(JW1 EV)

G80
Electrified
(RG3 EV)

5-Pin

GV70
Electrified
(JK1a EV)

Part Name

Part Number

Figure

No.

Insulation Cap –
Inlet Terminal
91691-GI010
5P Charge

1

Insulation Cap –
Inlet Terminal
91691-GI020
5P GND

2

Insulation Cap –
Inlet Terminal
91691-GI030
5P DC

3

Applied Position

①
②
③

NOTICE
Genesis EV repairs can only be performed at Genesis EV Certified Retailers.

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

SUBJECT:

Warranty Information:
Model

Op. Code

Operation

Op. Time

91690R00

Insulation Cap

Causal Part

Nature

Cause

I11

ZZ3

GV60
(JW1 EV)

G80
Electrified
(RG3 EV)

As Per Refer to Parts
WebLTS Table Above

GV70
Electrified
(JK1a EV)

NOTE 1: Normal warranty applies.
NOTE 2: Submit claim on Claim Entry Screen as “Warranty” type.
NOTE 3: Refer to the latest Digital Documentation Policy for requirements regarding capturing the
warrantable defect.
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 5: If a part is found in need of replacement while performing this TSB and the affected part is still
under warranty, submit a separate claim using the same repair order. If the affected part is out of
warranty, submit a Prior Approval request for goodwill consideration prior to performing the work.

TSB #: 24-EV-002G

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INSPECTION/REPLACEMENT OF EV CHARGING PORT INSULATION CAP

Service Procedure:

STUI
This TSB includes Repair validation photos. Refer to the latest Digital Documentation Policy for
requirements.
! WARNING
Verify that vehicle IGN is OFF before attempting repairs.

1.

Open the charging port (A).

GV60

A

G80 EV

A

i

Information

On G80 and GV70 electrified vehicles the
charge port is located on the front mesh
grille as shown to the right.

GV70 EV

A

TSB #: 24-EV-002G

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2.

Charging Port Inspection for Abnormal
Condition:
Inspect both charging areas:
•
•

AC charging terminals (B)
Quick (DC) charging terminal (C).

B

a) Check for any missing, damaged or
significantly deteriorated insulation caps.

C

b) Check for any foreign matter found inside
the port.

STUI
Using STUI, take a photo of the
charge port clearly showing the
abnormal condition and a piece of
paper with the last 6 digits of the
VIN and date of the repair.
Upload the photo to STUI.

3.

When foreign material is observed inside
the port:
•

Blow out any foreign material with shop air.

•

When it is necessary to assist in removing
any stubborn dirt that can’t be removed by
air, spray in a common electrical contact
cleaner. Blow out after with shop air again.

TSB #: 24-EV-002G

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4.

INSPECTION/REPLACEMENT OF EV CHARGING PORT INSULATION CAP

Missing/Removing and Replacing an
Insulation Cap:
•

Remove the insulation cap if it is damaged,
and/or significantly deterioriated.

•

Use needle nose pliers and gently grab and
pull outwards to remove the cap.

i Information
The photo shown at the right is an
example of a DC charging insulation cap
missing/removed at the left terminal (D).

D

The remaining steps show how to replace
a missing DC charging cap of this
example. Replacing an AC charging
insulation cap would be similar.

5.

Temporarily mount the replacement insulation
cap (E) on the DC terminal by pressing in firmly
by hand.

E

i

Information

In example at right, insulation cap is in
temporarily mounted position.
The DC terminal is shown removed for
demonstration purposes only.

TSB #: 24-EV-002G

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6.

To fully mount the insulation cap, press firmly
against the cap with a rod or similar object with
a flat tip.

i

Information

Example shown using the back of a
screwdriver.
7.

Service Procedure is complete.

TSB #: 24-EV-002G

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