File in Section:

Service Bulletin

Bulletin No.:
Date:

PIP5112A
June, 2014

PRELIMINARY INFORMATION
Subject:

Spark EV (BEV) High Voltage Battery Restriction And Exchange Process

Models:

2014 Chevrolet Spark EV with RPO EN0

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern
As part of our ongoing quality improvement process, effective 6/14/2013 the Drive Motor Battery, for the 2014 Spark
EV is being placed on restriction through the General Motors Technical Assistance Center (TAC). The dealership
must call TAC to establish a TAC case number and authorization. After doing so, TAC will then call the Electronic
Service Center (ESC) to order the Drive Motor Battery which is on exchange through the ESC.
Note: This Part Number should not be entered on the Warranty Claim. The Chevrolet Spark EV Drive Motor Battery
may also be referred to as the Rechargeable Energy Storage System (RESS).
Please review all of the information provided below prior to contacting the General Motors Technical Assistance
Center (TAC) @ 877-446-8227 (U.S.) or in Canada 1-800-263-7740 (English) or 1- 800-263-7960 (French) to review
case details.
Important: The following items should be reviewed and followed by the dealership technician.
• Prior to calling TAC, please make sure to collect the required information and complete the diagnosis provided
in the recommendations portion of this PI. Performing thediagnosis and obtaining the required information will
minimize the time spent on the telephone and avoid the need for multiple calls to TAC.
• Do not remove the Drive Motor Battery assembly covers unless instructed to do so by TAC or Engineering. A
GDS2 Session Log with Freeze Frame Data, Vehicle Wide DTCCheck with Module ID Information, besides the
Battery Energy Control Module (BECM) voltage data may be requested by TAC or Engineering
• Guidelines for honoring this exchange program are being strictly enforced. To obtain a replacement Drive Motor
Battery, the servicing Spark EV technician must providecustomer complaint and conditions as mentioned in this
document
• If the failure is due to one of the non-serviceable components the battery will be exchanged.
• Whenever performing battery repairs it is imperative that fasteners are torqued to specification and that G.S.I.
procedures are followed.
• The dealership must also use banding straps to secure the battery to the container base. Notify GM Technical
Assistance if banding equipment is not available at your dealership.
Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage
component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.
The High Voltage Disabling procedure will perform the following tasks:
1. Identify how to disable high voltage.
2. Identify how to test for the presence of high voltage.
3. Identify condition under which high voltage is always present and personal protection equipment (PPE) and
proper procedures must be followed.
Caution: Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
1. Safety glasses with appropriate side shields when within 50 feet of the vehicle, either indoors or outdoors.
2. Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protective gloves.
3. Visually and functionally inspect the gloves before use.
4. Wear the Insulation gloves at all times when working with the Drive Motor Battery assembly, whether the system
is energized or not. Failure to follow the procedures exactly as written may result in serious injury or death.

Recommendation/Instructions
Important: Only have a certified Spark EV technician follow the diagnostic procedures below prior to contacting
TAC. It will be necessary to connect GDS2 to record the Battery Capacity Code prior to disabling the 12V or High
Voltage systems.
1. Whether DTCs are current or history and procedure gives direction to remove internal components, STOP! Do
not clear codes prior to capturing data and calling TAC. Capture GDS2 Session Log stored Freeze Frame &
Failure Records prior to clearing any DTCs or performing any programming as mentioned above. It may be
necessary to road test the vehicle with GDS2 and MDI installed in order to capture a session log of the Hybrid
Powertrain Control Module 2 (HPCM 2) and Battery Energy Control Module (BECM) data when condition
occurs. TAC or Engineering may request that you e-mail the Session Logs to them in the future.
2. Call GM TAC to establish a TAC case. The latest version of PIP4902 can be used to email the GDS2 Session
Log that may need further review by TAC or Engineering. If a component has been identified as one of the
allowable internal battery repairs, instructions will be provided to the dealer. It is imperative that the technician
has completed all available Spark EV training including hands-on training as well as have all the required dealer
equipment, and all Personal Protection Equipment (PPE) is up to date.
3. After review of the diagnosis, TAC will use a case reference number and order an exchange Drive Motor Battery
through the ESC in order to have it shipped to your dealership. TAC will need the dealer’s hours of operation,
that they have the special tools / equipment and dealership personnel contact information.
3.1. This information, along with the Battery Identification Number (BIN) and the 4 digit battery capacity number,
will be needed for the TAC Consultant prior to ordering the battery. The battery pack 4 digit capacity code is
located in the HPCM 2 under the voltage data list. You may need the latest version of GDS 2 to see this 4
digit code.
3.2. If the battery is not out of the vehicle yet, you can find the BIN by installing the MDI and using GDS 2.
Access the BECM Module Information and look under the identification information section and the sixteen
digit number will be listed under the GDS2 parameter: Hybrid/EV Battery Identification Number (BIN). You
will need to record the BIN and supply it to TAC when ordering a battery. The battery also has a 16 digit
Battery Identification Tag (B.I.N.) that is located on the right side of the battery. You can locate the tag and
record the B.I.N. upon removal. As of date, the BIN is the bottom most number on the label (See Photo
Below).

3468543

4. After verifying that the high voltage systems are disabled, remove battery assembly per SI procedures.
Important: The Battery pack has two ground straps that are attached to the battery. ONLY remove the ground
straps that are attached to the battery. The new battery will NOT come with the 2 ground straps already attached.
Important: The exchange unit will be shipped without coolant. As part of the battery removal process, all coolant
should be drained from the drive motor battery.

Follow G.S.I. procedure for proper coolant type, fill and coolant bleed procedures. After the Battery has been
removed from the vehicle (see G.S.I. procedure), and before placement into the shipping container, prepare the
battery for return by performing the following:
1. Install Coolant plugs (2) in coolant lines. Coolant plugs can be removed from the new service battery assembly
and installed in the returned battery. Additional coolant plugs (GM P/N 22770854) can be ordered if they are
needed.
2. Install the Manual Service Disconnect (MSD) Cover. The MSD cover can be removed from the new service
battery assembly and installed in the returned battery. Additional MSD covers (GM P/N 22989605) can be
ordered if they are needed. The MSD lever should remain with the vehicle and not be returned with the battery
assembly.
3. Install the High and Low Voltage Connector Covers. The covers can be removed from the service battery and
installed on the returned battery. In order to properly prepare the used battery for shipping and to insure safe
shipment, all of the above steps must be followed.
Caution: With the Drive Motor Battery on the EN 48244 Support Table, slowly raise the support table to the vehicle.
Use a punch or alignment tool to get the Drive Motor Battery into position. Avoid making contact with the front of the
drive motor battery with the body so damage does not occur to the studs that are used to attach the windage or aero
panels upon final installation.
Danger: The High Voltage Drive Motor Battery must be protected when outside of the vehicle. This is why
the battery must be immediately placed in the original shipping container.
4. Follow current SI Procedure to complete installation of the Drive Motor Battery.
Important: Programming steps: (Please carefully review steps 1-5).
4.1.Perform K16 Drive Motor Generator Battery Energy Control Module (BECM) programming when replacing
the Drive Motor Battery. This will also program the Module Balance Boards (MBBs) and Current Sense
Module (CSM) which may take approximately four minutes.
4.2.Turn the ignition off, disconnect all devices, close the door and allow the vehicle to enter a sleep cycle (fully
power down) for at least two minutes.
4.3.After SPS programming the BECM, follow current SI procedure. Using GDS2, select Control Functions,
perform the Hybrid / EV Pack Capacity Reset and then Battery Capacity Relearn in Hybrid Powertrain
Control Module 2.
4.4.When SI procedures are complete, you will have to drive the vehicle in Sport Mode with the vehicle in Low
Gear for approximately 5 miles (8 km). This will pack the most energy in the battery during charging and
regeneration and exercises the coolant valves and pumps. When performing the 5 mile (8 km) drive cycle,
drive vehicle in slalom (side to side motion) to purge any air from the battery pack cooling plates. After the
drive cycle, check for codes and top off the coolant system.
Important: Low coolant or the incorrect coolant could result in internal battery or coolant heater damage
4.5.Follow current SI Procedure to complete installation of the Drive Motor Battery.
Fully charge Drive Motor Battery before delivering the vehicle to the customer.
Danger: The High Voltage Drive Motor Battery must be protected when outside of the vehicle. This is why
the battery must be immediately placed in the original shipping container.
STORAGE GUIDELINES:
4.1.Store the Drive Motor Battery flat.
4.2.Store the Drive Motor Battery in an environmentally protected area.
4.3.Maintain the Drive Motor Battery at room temperature.
4.4.Protect the Drive Motor Battery from exposure to liquids.
4.5.Protect the Drive Motor Battery from physical damage.
4.6.Store the Drive Motor Battery in a limited-access area.
Danger: Failure to follow these guidelines may result in serious injury or death
PARTS RETENTION AND RETURNS - UNITED STATES DEALERS
Parts Return Request (WPC) A Special Parts Return Request will be faxed to you with proper shipping
instructions. Do NOT wait for the warranty claim to be paid before returning the failed used battery.
Please follow WPC guidelines below:
1. Do NOT send a battery back without a Special Parts Return Request.
2. Do NOT send the battery back to the ESC.
3. Do NOT send battery back to the WPC.

4. Do NOT return battery in any other container than the container (crate) that the new battery was delivered in.
The removed unit must be returned complete in the original exchange shipping container.
5. The Special Parts Request will provide a request number. This request number must be placed in the outside
shipping envelope along with the TAC Case number. Dealers need to place a new envelope inside the battery
crate with completed Spark EV Battery Exchange information including the TAC Case number along with a copy
of the Job Card (RO), including the technician’s comments, DTCs, and diagnostics. It is recommended that this
be taped to the battery inside the container. Failure to place this information both outside and inside the battery
shipping container may delay the processing of your return. Do not ship a battery back without an official WPC
Request.
Important: Failure to return the battery by the due date will result in the dealership being debited the entire warranty
claim (parts and labor).
Important: If you do not receive the WPC Special Part Request, call 248-371-9939 to obtain the proper paper work
in order to return the failed Drive Motor Battery.
SHIPPING PREPARATION:
1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling.
2. Remove the Drive Motor Battery from the vehicle as outlined in Drive Motor Generator Battery Replacement
in SI.
3. Tighten any fasteners that were loosened or removed to the original torque specification during Drive Motor
Battery removal.
4. Remove any plastic shipping plugs or covers from the new unit and install them on the Drive Motor Battery to be
returned.
5. Write the TAC case reference number on the drive motor battery assembly in a visible location.
6. Write the TAC case reference number on the repair order.
7. Place the Drive Motor Battery into the shipping container and attach the completed return shipping tag to the
Drive Motor Battery.

3943206

8. It is important to package the Drive Motor Battery upon return exactly as the new Drive Motor Battery was
received. Zinc-Plated Steel Lag Screws for Wood, 5/16" Diameter, 2-1/2" Length are used to secure the battery
pack to the crate base. The dealership must also use banding straps to secure the battery to the container base.
The container top or “bonnet” must also be banded to the container base as pictured below.
Important: Notify Technical Assistance if banding equipment is not available at the dealership.

3943204

1. Banding Straps
2. Access Door

3943203

3. Banding Straps
4. Access Door

3943205

5. Banding Straps
SHIPPING INSTRUCTIONS:
1. Place a copy of the Special Parts Return Request, repair order with technician comments, along with the
completed "Spark EV Battery Product Feedback Form” (available in Global Connect) and place into the plastic
envelope. The bill of lading and customs papers (for cross border shipments) should also be inserted into the
plastic envelope. Remove the original shipping label and attach the plastic envelope with the return shipping
label on it to the container.
2. Label the outside of the shipping container with the Part Return request number and the TAC case reference
number. Refer to Corporate Bulletin Number 99-00-89-019 for detailed shipping information.
3. Follow the shipping instructions received in the Special Parts Request.
4. Have the driver sign the bill of lading. Retain a copy of the signed bill of lading and attach your copy to the
original repair order. This will be your proof of returning the Drive Motor Battery.
5. Ship the Spark EV battery with appropriate paperwork to:
A123 Systems
39000 Seven Mile Road
Livonia, MI 48152
RMA# PR04200 VIN: _____________ (example: VIN XXXXXXXX)

PARTS INFORMATION
No Part Number should be entered for exchange components. Applicable miscellaneous items such as coolant
should be added to the part allowance amount and claimed in the Parts Cost column and not included in the Net
Amount (DMN) column of the warranty claim.

CANADIAN SERVICE AGENTS ONLY
All Spark EV batteries must be returned with completed documentation including battery return worksheets with TAC
Case Number and VIN.
Note: Failure to return the battery will result in the dealership being debited the entire warranty claim (parts and
labor.) For dealers in Canada, the return of failed batteries will be handled as outlined in Parts Bulletin
GMP2013-081.

SHIPPING PREPARATION
1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling
2. Remove the Drive Motor Battery from the vehicle as outlined in Drive Motor Generator Battery Replacement
in G.S.I
3. Tighten any fasteners that were loosened or removed during Drive Motor Battery removal to the original torque
specification
4. Remove any plastic shipping plugs or covers from the new unit and install them on the Drive Motor Battery to be
returned
5. Write the TAC case reference number on the drive motor battery assembly in a visible location.
6. Write the TAC case reference number on the repair order.

7. Place the Drive Motor Battery on the cradle into the shipping container
8. Place the completed "Spark EV Battery Product Feedback Form” (available in Global Connect) inside the crate
with the failed battery. Dealers need to place a new envelope inside the battery crate with completed Spark EV
Battery Exchange information including the TAC Case #, along with a copy of the Job Card (RO) including the
technician’s comments, DTCs, and diagnostics. It is recommended that this be taped to the battery inside the
crate
9. It is important to package the Drive Motor Battery upon return exactly as the new Drive Motor Battery was
received. Zinc-Plated Steel Lag Screws for Wood, 5/16" Diameter, 2-1/2" Length are used to secure the battery
pack to the crate base. The dealership must also use banding straps to secure the battery to the container base.
The container top or “bonnet” must also be banded to the container base as pictured below. Notify Technical
Assistance if banding equipment is not available at the dealership

CANADIAN SHIPPING INSTRUCTIONS
Canadian Dealers should follow the steps below to return a failed battery:
1. Contact Rob Carlyle – CCA (905-644-5385) or Kris Muller – CCA (905-644-5159) to arrange battery/section
pick-up.
2. Complete the required return hazardous goods shipping paperwork (302C form)
3. The DDS assigned carrier will pick up this battery.
4. Canadian Dealers do NOT return batteries to the ESC or to the WPC

Parts Information
Model Year

Part Name

Part Number

2014

High Voltage Battery Assembly

23176402

Warranty Information
Labor Operation

Description

Labor Time

Part Allowance

5030630

Drive Motor Battery
Replacement

Use Published Labor
Operation Time

$400.00

Add

Administrative Allowance

0.2 hr

Add

Road Test - Data Snapshot

0.3 hr

Note: For those batteries not requested back thru the WPC for Root Cause a battery recycling process will be
published shortly. Li-Ion batteries must be properly packaged, transported and, recycled using published procedures
that are compliant with federal, state/provincial, and local laws and regulations.
For vehicles repaired under warranty, use:
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is
resolved without completing every step, the remaining steps do not need to be performed.