Bulletin No.: PIP5112D
Date: May-2015

Subject:

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

Models:

2014 -2015 Chevrolet Spark EV
with RPO EN0

This PI was superseded to update Part Information. Please discard PIP5112C.
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 as of 08/06/2014, the Drive Motor Battery for the 2014 - 2015 Spark EV and several internal
components are 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 to order the Rechargeable Energy Storage System (RESS) or any of the internal components listed below. TAC or Engineering
will then provide guidance if internal components should be replaced or if the RESS should be replaced. If it is to be replaced, TAC will call the nearest Electronic
Service Center (ESC) to order the Drive Motor Battery. At this point in time, the 2015 Spark EV Drive Motor Battery is on exchange and not to be opened for
service unless authorized by GM TAC and Engineering.
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: Prior to calling TAC, please make sure to collect the required information and complete the diagnosis provided in the recommendations portion of
this PI. Completing the diagnostics and obtaining all required information will minimize downtime, multiple calls to TAC, misdiagnosis, or unnecessary component
replacement.
The following items should be reviewed and followed by the dealership technician.
–

A GDS2 Session Log with Freeze Frame Data, Vehicle Wide DTC Check with Module ID Information, any Battery Energy Control Module (BECM) or
HPCM2 data menus, will normally 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 provide customer 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 when shipping the Drive Motor Battery.

Note: Please notify GM Technical Assistance if banding equipment is not available at your dealership when requesting a Drive Motor Battery. There is a limited
number of Banding Kits available when the Drive Motor Battery order is being placed through the ESC. It may be necessary to obtain a Banding Kit through
existing dealership resources
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

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.

Do not clear codes prior to capturing data. GDS2 Session Log Freeze Frame & Failure Records should be reviewed prior to clearing any DTCs or
performing any programming. Regardless if DTCs are current, history or G.S.I. repair procedure gives direction to remove any internal components or
perform programming,

2.

It may be necessary to road test the vehicle through several drive cycles with GDS2 installed in an attempt to capture relevant data in the GDS2
Session Log while attempting to duplicate the concern.

3.

The GDS2 Session Log should include a Vehicle Wide DTC Check with Module ID Information, any relevant failure records, module data from the
Hybrid Powertrain Control Module 2 (HPCM 2), Battery Energy Control Module (BECM) while attempting to duplicate the customer’s concern in certain
conditions or driving habits. TAC or Engineering may request that you e-mail the GDS2 Session Logs to them for immediate review.

4.

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.

5.

If the battery is not out of the vehicle yet, you can find the BIN by installing the MDI and using GDS2. 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 number on the bottom label (See Photo Below).

1.

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.

2.

After the data is reviewed, 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.

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:

2

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).
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.

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.

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.

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

5.

Follow current SI Procedure to complete installation of the Drive Motor Battery and 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:
1.

Store the Drive Motor Battery flat.

2.

Store the Drive Motor Battery in an environmentally protected area.

3.

Maintain the Drive Motor Battery at room temperature.

4.

Protect the Drive Motor Battery from exposure to liquids.

5.

Protect the Drive Motor Battery from physical damage.

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).
3

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.

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: During your call to TAC, inform them if banding equipment is not available at the dealership. Banding Kits may need to be ordered from the ESC.

1.

Banding Straps

2.

Access Door

4

3.

Banding Straps

4.

Access Door

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:

Battery Refurbishment
Dock 16
Brownstown Battery Assembly Plant
20001 Brownstown Center Drive
Brownstown, MI 48134
Attention: Brett Powell
+1 248 866 9010

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:

5

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.