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How I replaced broken charge port on Fiat 500e
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Fiat 500e Charge Port Replacement

How I replaced a broken charge port on 2015 Fiat 500e

May 23, 2021

Sometime into our ownership of a used 500e, the charge port became loose when connecting the charge cable. Upon closer inspection, we could see where it had been previously broken and glued. That repair failed. Looking at 500e forum, it was clear that dealership repair was outrageously expensive but that there was a fairly straightforward DIY fix. Fortunately, the repair does not require any major change to the electrical lines. It is just removing the current electrical pins from the broken plastic port housing and placing them in a new plastic port housing.

A search on eBay for a replacement charge port yielded a hit for a port with instructions that matched the process mentioned as successful in the forum. I'm documenting it for my personal future reference. The whole job took a few hours with me taking my time, some breaks, and taking photos.

If you choose to follow, your actions are your own. I can not be held responsible for any errors nor the outcomes of your actions. You assume all the risks associated with automotive and electrical repair.

Process

The process I used followed the instructions supplied with the new port. They were detailed and complete but contained no drawings or images for guidance. I'm documenting my process here for better reference (when I have to do it again)

Prep and Access

Port Removal

Port Installation

Test

Re-assembly

Failure Analysis

This failure reveals the weakness of the charging port. If excessive force is applied to the charging cable, the stress can overcome the strength of the charging port in the vehicle and snap the housing. Excessive forces are most likely applied by bumping the charging handle or tripping over the charging cable. Anyone can potentially do this either accidentally or purposefully. So I suspect this problem will eventually repeat itself.