Bulletin No.: PIC6194C
Published date: 06/14/2017

Preliminary Information
PIC6194C (Malibu HEV) High Voltage Drive Motor Battery TAC Restriction and Exchange Program
Models
Brand:
Chevrolet

Model:
Malibu

VIN:

Model Years:
2016 - 2018

from
All

Engine:

to
All

LKN

Transmissions:
MKE

Supersession Statement
This PI was superseded to update the battery return process and update model years. Please discard PIC6194B.
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 April 14, 2016 the High Voltage Drive Motor Battery, for the 2016-2018
Chevrolet Malibu Hybrid (GM part numbers: 24280416, 24282982, 24282981, 24282983, 24281489 ) are being placed on
restriction through the GM Technical Assistance Center (TAC). We will also put the following internal battery parts on restriction.
1) HIgh Voltage Battery Disconnect Relay ( Also known as A28 Hybrid/EV Battery Contactor Assembly ) GM Part Number: 24284374.
2) The Hybrid Powertrain Control Module (HPCM2) GM Part Numbers: 24279859, 24283920
3) 14 Volt Power Module (APM) GM Part Number: 24279953.
NOTE: Please review all of the information provided below prior to contacting the GM Technical Assistance Center (TAC) @ 877-4468227 (U.S.) or in Canada 1-800-263-7740 (English) or 1-800-263-7960 (French) to review case details.
This P/I will explain the Drive Motor Battery Exchange Program for the 2016-2018 Chevrolet Malibu. It is expected that this exchange
program will remain in effect for a minimum of 12 months. Product teams continually seek valuable information for engineering
improvements.
This exchange program is also designed to gain important feedback on this new High Voltage Drive Motor Battery assembly including
validating the service diagnostics, repair, and re-qualification procedures.
During the initial exchange period, components inside the drive motor battery assembly will not be replaced.
As more repairs are allowed, internal to the High Voltage Drive Motor Battery, this exchange P/I will be updated.
Do not remove any Drive Motor Battery assembly covers during this exchange period unless instructed to do so by TAC.

PARTS RETENTION AND RETURNS UNITED STATES SERVICE AGENTS ONLY
All Li-Ion drive motor batteries and battery sections need to be returned for possible refurbishment. If the batteries are not returned
within 30 days, the dealer will be charged back the value of a replacement battery. These charges are substantial.
There are two different ways the Li-Ion drive motor battery or battery section could be returned.

1. Oklahoma City Determination Center: If you do not receive a WPC special request within 3 days of completing the repair contact
CCA Logistics CCA Logistics (810-866-9300) [email protected]. It is expected that the majority of batteries will
go thru this process.
2. Warranty Parts Center (WPC): A Special Parts Return Request will be faxed or emailed to you with proper shipping
instructions/location. You must use the BOL that is sent to you. Do NOT wait for the warranty claim to be processed before
returning the failed used drive motor battery. WPC guidelines below:
Do NOT send a battery back without a Special Parts Return Request.
DO NOT ship drive motor batteries directly to the WPC.
Do NOT return battery in any other container than the container (cocoon) that the new/refurbished battery was delivered
in. The removed unit must be returned complete in the original exchange shipping container. Refer to the specific drive
motor battery exchange bulletin in eSI for the vehicle being repaired.
Note: Failure to return the battery or battery section by the due date will result in the dealership being debited the entire warranty claim
(parts and labor) as well as assessment for the value of the failed pack.
Note: If you do not receive a direction of where to ship the battery or battery section back, verify that you do not have an existing
open WPC Request. If you don't have a WPC Special Part Request via fax or e-mail from WPC, contact CCA Logistics (810-866-9300
[email protected] for shipping instructions and the proper paper work in order to return the failed Drive Motor Battery
or battery section.

Oklahoma City Determination Center Shipping Instructions:
Note: Never ship a damaged or compromised battery without prior approval. All hazardous materials must be shipped in accordance
with all local, state, and federal laws.

1.
2.
3.
4.
5.

Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling. Refer to eSI.
Remove the Drive Motor Battery from the vehicle as outlined in Drive Motor Generator Battery Replacement in eSI.
Tighten any fasteners that were loosened or removed during Drive Motor Battery removal to the original torque specification.
Remove any plastic shipping plugs or covers from the new unit and install them on the Drive Motor Battery to be returned.
Place a copy of the repair order with technician comments, and the completed "Battery Product Feedback Form" 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.

6. Place the Drive Motor Battery into the shipping container and attach the completed return shipping tag to the Drive Motor Battery
Cocoon.
Determination Center Shipping Address
Spiers New Technologies
50 NE 42nd St
Oklahoma City, Oklahoma 73105-2201
Contact Brian Enis (p) 405-274-5911

WPC Shipping Instructions:
1. The Special Parts Request will provide a request number. This request number must be placed in the outside shipping envelope

2.

3.
4.
5.
6.
7.

along with the TAC Case number. Dealers need to place a new envelope inside the battery cocoon TAC Case #, along with a
copy of the Job Card (RO) including the technician's comments, DTCs, diagnostics, and completed "Battery Product Feedback
Form".
The bill of lading and customs papers (for cross border shipments) should also be inserted into the outer plastic envelope.
Remove the original shipping label and attach the plastic envelope with the return shipping label on it to 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.
Label the outside of the shipping container with the Part Return request number and the TAC case reference number. Refer to
Corporate Bulletin Number 99-00-89-019F for detailed shipping information
Contact Central Transport at 586-467-1900 for pick-up of removed battery. If lift gate service is necessary, please request it at the
time of arranging pick-up service. The number is also on the BOL that is sent to you from WPC.
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.
Ship the battery Third Party Prepaid Freight Collect with appropriate paperwork to address provided.
Once the battery is shipped, please e-mail [email protected] with tracking number and Special Parts Return Request Number.

This P/I will also be revised to announce the updates to the Drive Motor Battery Exchange program.
During the launch period of the 2016-2018 Chevrolet Malibu Hybrid the Drive Motor Battery may also be referred to as the Lithium Ion
High Voltage Battery.
The Exchanged Drive Motor Batteries will be refurbished and tested to provide a capacity greater to or equal to the replaced battery.
Prior to calling TAC, please make sure to complete the Malibu Battery Exchange required Information and diagnosis provided in the
recommendations portion of this PI.
Performing the diagnosis and obtaining the required information will minimize the time spent on the telephone and avoid the need for
multiple calls to TAC.
Guidelines for honoring this exchange program are being strictly enforced.
To obtain a replacement drive motor battery, the servicing Malibu hybrid technician must provide TAC with a detailed customer
complaint, conditions, diagnostic trouble codes (DTC.S) and other useful information as outlined below in the recommendations field.
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
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 protectors.
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.

Recommendations / Instructions
Please have a certified Malibu technician follow the diagnostic procedures below prior to contacting TAC.
1. If DTCs are present and procedure gives direction to remove internal components; stop, capture GDS2 Session Log stored data, and
test drive vehicle with GDS and MDI, and capture a snap shot of the Hybrid Powertrain Control Module 2 (VICM) data when condition
occurs. See Latest version of PIP4902 for correct session logs data collection and procedure for emailing. TAC may request that you email the Session Logs to them. Do not clear codes prior to capturing data and calling TAC.
2. If DTCs are not present, refer to “Symptoms - Hybrid Controls " in SI.
3. If any diagnostic procedure gives direction to remove internal components, stop and call TAC, internal components should not be
removed at this time.
4. Upon review of the diagnosis, TAC will establish a case reference number and make arrangements for ordering a part or an
exchange battery assembly.
5. After verifying that the high voltage systems are disabled, remove battery assembly per SI procedures.
6. Prior to contacting TAC, check with your parts personnel for the parts department hours of operation (including Saturdays if open)
and the name of the parts contact that will be handling the battery pack. This information along with the battery identification number
(BIN) needs to be supplied to the TAC consultant prior to ordering the battery.
6.1 The battery has a battery identification tag that is located on the side of the battery. Locate the tag and record the 16 digit battery
identification number (BIN). The BIN is the bottom most number on the label and it starts with a "T" indicator (See Photo Below). 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 Hybrid Powertrain Control
Module 2 data list and look under the identification information section and the sixteen digit number will be listed under the
parameter: Hybrid/EV Battery Pack Identification Number.

7. You will have to advise TAC if your dealer has a working fork-lift for loading and unloading the battery pack assembly.
8. Perform Hybrid Powertrain Control Module 2 (HPCM2) reprogramming when replacing the new battery pack as well as check and
reprogram all electric propulsion control modules with the latest calibrations.
After the Battery has been removed from the vehicle (see service manual procedure), and before placement into the shipping cocoon,
prepare the battery for return by performing the following:
1) Install the Manual Service Disconnect (MSD) Insert. The MSD Insert can be removed from the new service battery assembly and
installed in the returned battery.
Note: The MSD lever should remain with the vehicle and not be returned with the battery assembly.
Danger: The high voltage (HV) battery must be protected when outside of the vehicle. This is why the battery must be immediately
placed in the original shipping container (cocoon).

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 Information
Model Year

Part Name

Part Number

2016-2018

Hybrid Battery Pack Assembly

24282982,
24282981,
24282983,
24280416,
24281489

2016-2018

Hybrid Powertrain Control
Module (HPCM2)

24279859
24283920

2016-2018

Drive Motor Relay Contactor
Assembly (BDU)

24284374

2016-2018

14V Accessory DC Power
Control Module (APM)

24279953

Warranty Information
No Part Number should be entered for exchange components on the warranty claim.
Exchange battery is delivered to the dealer by Battery Spiers New Technologies (SNT).
Dealer is not billed for an exchange component unless it is not returned within the prescribed time period.
There will be a $400 handling allowance for this exchange.
Applicable handling allowance and miscellaneous items 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.
Labor
Operation

Description

Labor Time

Part Allowance

Drive Motor

Use Published

Generator Battery

Labor Operation

Replacement

Time

5030290

Drive Motor
Generator Battery
Section
Replacement

Use Published
Labor Operation
Time

Add

Road test – Data
snapshot

0.3 hr

Add

Additional time to
balance section

1.0 hr

5031760

High Voltage Battery
Disconnect Relay
Replacement

Use Published
Labor Operation
Time

5010220

14V Accessory DC
Power Control
Module
Replacement

Use Published
Labor Operation
Time

5010080

Hybrid Powertrain
Control Module 2
Replacement

Use Published
Labor Operation
Time

5031030

$400.00*

$250.00*

*Additional Administrative Allowances may be submitted as follows:
In the U.S. and Canada – Add $20 to the Net/Admin Allowance (for a total allowance of $420 or $270 as applicable).

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.

© 2016 General Motors. All Rights Reserved.