Kia EV6 V2L Internal Outlet Interlock Mechanism & Terminal Carrier

Overview

A frequent point of failure on the Kia EV6 (and related Hyundai E-GMP vehicles) is the in-cabin 120V AC under-seat Vehicle-to-Load (V2L) outlet.

Inside the factory receptacle, an internal plastic rocker mechanism detects when a plug prong is inserted and depresses a microswitch on the circuit board to tell the vehicle's inverter to deliver 120V AC power. Over time the fragile OEM retention towers flex and spread apart, or the lever snaps. When the switch fails to trigger, the outlets indicator LED will always be blue (standby), even when a plug is inserted which when functional would turn the LED green, or if the unit is broken in some other way, the LED could be lit red.

Repair Guide

Note: I do not know if this part works with non-US versions of this part. Let me know if it does.

You can find disassembly instructions of the outlet here: https://imgur.com/a/pbAzoX3

I recommend you disconnect your batteries (HV and 12V) as documented on the internet/car manual, this is a very easy step.

Unhook the two cables connecting the outlet to the car. The white one is a typical "squeeze" electronics cable while the other is made of two pieces, the main body is orange and there is a yellow piece. Push the yellow piece and it will click, unlocking the cable. Be gentle when pushing the yellow piece as I did break mine during the repeated assembly/disassembly I did while developing this fix.

You can find a guide at getting under the seat to access the outlet here: https://youtu.be/jpA-26kksXE

Printing/Slicer Settings

The uploaded 3MF contains the settings I used to print on an Elegoo Centauri 2, though I did print near working prototypes on a Bambu P1S just fine as well with similar settings.

Being in a car, this cannot be printed in PLA and being in contact with electricity I would not print this with any carbon fiber (CF) infused filament (as CF is conductive). I printed this is PCTG, I imagine ASA or ABS might be good as well.

I have updated this model to bake in supports. The model also now prints the part 45° from the bed, this greatly increases the strength of the retention clips and allows the lever to be printed in place.

The only deviation I made here from usual settings is I printed at 260°C to facilitate layer adhesion and prevent the clips from breaking.

0.12 mm Fine, 0.4mm Nozzle

5 wall loops

Disable supports

Brim off

Assembly

In the new version everything is printed as one part. Simply remove all supports marked in the diagram in red and insert the brass inserts from the OEM part.

After the print is assembled, push the printed part into its receiver, the clips should lock into the corresponding OEM slots. You can test if the print is working at this point by pushing on the back of it to hold it in and inserting a plug. The plug should insert smoothly all the way and the lever should actuate. You should hear an audible click indicating the button is pressed if you gently insert a plug. If you do not hear a click, try reassembling, sometimes for reasons I don't understand this can make it work.

Note that it may not reach the top of its hole and it may not fall down when the plug is taken out, these are both ok. The button inside the assembly should push it down.

Notes

This print is not a 1:1 reproduction of the OEM part, it alters small parts of the original in order to hopefully increase its longevity as well as improve its printibility. I did try to add a clip at the top of the towers, to prevent them from deforming, but I could not work out how to do it without interfering with the mating part. I have tested that this part does work, but as of yet I have only been using it for a short time, so it may fail with repeated usage.

Please feel free to remix if you see improvements. I do not know if this part works with non-US versions of this part.

DISCLAIMER OF LIABILITY, SAFETY WARNING & INDEMNIFICATION AGREEMENT

⚠ CRITICAL ELECTRICAL & AUTOMOTIVE SAFETY WARNING

This 3D CAD model interfaces with an active 120V AC vehicle-to-load electrical circuit and vehicle electronics. Working on automotive high-voltage systems carries inherent risks of electric shock, electrocution, electrical fires, short circuits, vehicle damage, severe personal injury, and death.

Always ensure the vehicle is fully powered off, the 120V AC inverter is disengaged, and high-voltage safety precautions are observed prior to accessing or disassembling any electrical components.

3D-printed thermoplastic materials have specific thermal, electrical, and mechanical limitations. Using inappropriate materials (e.g., standard PLA) in hot vehicle environments may cause mechanical deformation, electrical failure, or fire hazards.

If you are not qualified to service automotive electrical systems, seek professional installation by a certified technician.

1. "AS IS" WARRANTY DISCLAIMER

THIS 3D MODEL, CAD DATA, INSTRUCTIONS, AND ASSOCIATED FILES (COLLECTIVELY, THE "WORK") ARE PROVIDED SOLELY FOR INFORMATIONAL, EXPERIMENTAL, AND EDUCATIONAL PURPOSES ON AN "AS IS" AND "AS AVAILABLE" BASIS, WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESS OR IMPLIED.

TO THE FULLEST EXTENT PERMISSIBLE UNDER APPLICABLE LAW, THE CREATOR/AUTHOR EXPRESSLY DISCLAIMS ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO:

WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE;

WARRANTIES AGAINST HIDDEN DEFECTS, STRUCTURAL DEFICIENCIES, OR ELECTRICAL NON-COMPLIANCE;

WARRANTIES REGARDING VEHICLE SAFETY, CRASHWORTHINESS, WARRANTY RETENTION, OR REGULATORY COMPLIANCE.

THE ENTIRE RISK AS TO THE QUALITY, DURABILITY, ACCURACY, AND PERFORMANCE OF ANY PHYSICAL OBJECT PRODUCED USING THESE FILES RESTS SOLELY WITH THE USER.

2. ASSUMPTION OF RISK

BY DOWNLOADING, SLICING, 3D PRINTING, INSTALLING, OR OTHERWISE USING ANY FILES PROVIDED HEREIN, YOU ACKNOWLEDGE AND AGREE THAT:

You have voluntarily chosen to fabricate and install an aftermarket, non-OEM, non-certified component into an automotive electrical system.

You assume full responsibility for selecting appropriate slicing settings, print tolerances, and heat-resistant/flame-retardant filament materials (e.g., PETG/ABS/ASA).

You expressly assume all known and unknown risks of property damage, vehicle warranty invalidation, electrical failure, fire, personal injury, disability, or death resulting from the manufacturing, assembly, fitment, or operational failure of this part.

3. INDEMNIFICATION & HOLD HARMLESS

TO THE MAXIMUM EXTENT PERMITTED BY LAW, YOU AGREE TO INDEMNIFY, DEFEND, AND HOLD HARMLESS THE AUTHOR/CREATOR OF THESE FILES FROM AND AGAINST ANY AND ALL CLAIMS, LIABILITIES, LAWSUITS, DEMANDS, DAMAGES, LOSSES, COSTS, PENALTIES, OR EXPENSES (INCLUDING REASONABLE ATTORNEYS' FEES) ARISING OUT OF OR IN ANY WAY CONNECTED WITH:

YOUR ACCESS TO, DOWNLOAD, MODIFICATION, OR DISTRIBUTION OF THESE FILES;

THE 3D PRINTING, FABRICATION, ASSEMBLY, OR INSTALLATION OF ANY COMPONENT PRODUCED FROM THESE FILES;

ANY PHYSICAL INJURY, ELECTROCUTION, VEHICLE DAMAGE, ELECTRICAL MALFUNCTION, OR FIRE RESULTING DIRECTLY OR INDIRECTLY FROM THE USE OR MISUSE OF THIS DESIGN;

ANY CLAIM BY A THIRD PARTY (INCLUDING PASSENGERS, SUBSEQUENT VEHICLE OWNERS, OR INSURERS) RESULTING FROM THE OPERATION OR FAILURE OF THE 3D-PRINTED PART.

4. VEHICLE WARRANTY & REGULATORY NOTICE

Modifying factory vehicle wiring or internal power receptacles may void portions of your vehicle manufacturer’s warranty and may not comply with local motor vehicle safety standards (FMVSS/DOT/ECE) or electrical regulatory codes (UL/NEMA/SAE). The creator of this design is not affiliated with, sponsored by, or endorsed by Kia Corporation, Hyundai Motor Group, or any of their affiliates.