Bulletin No.: PIC6127H
Published date: 06/28/2017

Preliminary Information
PIC6127H (Volt) High Voltage Drive Motor Battery TAC Restriction and Exchange Program
Models
Brand:
Chevrolet

Model:
Volt

VIN:

Model Years:
2016 - 2018

from
All

Engine:

to
All

L3A

Transmissions:
MKV

Supersession Statement
This PI was superseded to update battery return process and add model years and remove parts number off restriction. Please
discard PIC6127G.
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 August 24, 2015 the High Voltage Drive Motor Battery and Battery
sections, for the 2016-2017 Chevrolet Volt is being placed on restriction through the GM Technical Assistance Center (TAC).
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 Volt. 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 e-mailed 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.

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 Volt the Drive Motor Battery may also be referred to as the Lithium Ion High
Voltage Battery.
The Exchanged Drive Motor Batteries and battery sections 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 Volt 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 volt 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 Volt 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) and BECM data when
condition occurs. See Latest version of PIP4902 for correct session logs data collection and procedure for emailing. TAC may request
that you e-mail 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 an exchange battery
assembly
5. After verifying that the high voltage systems are disabled, remove battery assembly per SI procedures.
Note: The Battery pack has a ground strap that are attached to the battery. ONLY remove the ground strap on the vehicle side. The
new battery will come with the 2 ground straps already attached.
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) and the 4 digit battery capacity number will need to be supplied to the TAC consultant prior to ordering the battery.
6.1 The battery pack 4 digit capacity code is located in the HPCM 2 under the voltage data list. You need to make sure that you have
the latest version of GDS 2 to see this 4 digit code.
6.2 The battery has a battery identification tag that is located on the right 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 Battery
Energy Control Module 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.
Note: The exchange unit will be shipped without coolant. Follow SI procedure for proper coolant and fill procedures. Low coolant or
wrong coolant could result in internal battery damage. For additional information on how to properly bleed the battery cooling system,
please see the latest version of PI: PIP4859. For information on the proper battery coolant, please see the latest version of PI: PIP4910
8. Perform Drive Motor Generator Battery Control Module (BECM) reprogramming when replacing the new battery pack as well as check
and reprogram all electric propulsion control modules with the latest calibrations.
Note: The exchange unit will be shipped without coolant. Follow SI procedure for proper coolant and fill procedures. Low coolant or
wrong coolant could result in internal battery damage. For additional information on how to properly bleed the battery cooling system,
please see the latest version of PI: PIP4859. For information on the proper battery coolant, please see the latest version of PI: PIP4910
9. Next reset the Hybrid / EV battery pack data . This can be found in GDS 2 under: Hybrid Powertrain Control Module 2 and selecting
Configuration/Reset Functions.
10. After SPS programming the BECM, you will have to drive the vehicle in Mountain 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
battery pack cooling plates. After the drive cycle, check for codes and top off the coolant system.
11) If replacing just a battery section, please make sure you have the EL-51763 High Voltage Battery Section Covers, EL-50115 Battery
Section Lifting adapter, and the EL-48264 Battery Pack Lifting Adapter to help remove the battery section and then balance the battery

section before installing the battery cover.
12. Fully charge the High Voltage Battery before delivering the vehicle to the customer.
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 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. Note: As part of the battery removal
process, all coolant should be drained from the drive motor battery.
2) 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.
In order to properly prepare the used battery for shipping and to insure safe shipment, all of the above steps must be followed.
Note: The used battery must be removed and returned with a battery assembly lifting fixture (GM Special Tool EL-49976.) This lifting
fixture will be attached to the used battery and placed in the shipping cocoon. Each new service battery will come with a battery
assembly lifting fixture for use during installation. You will keep this fixture for servicing future battery removals.
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

HIgh Voltage Battery Section 1

19333491, 23348446

2016-2018

High Voltage Battery Section 2

19333492, 23348447

2016-2018

HIgh Voltage Battery Section 3

19333493, 23348448

2016-2018

HIgh Voltage Battery Assembly

23348947, 19355708, 24286744,
24289394, 24289393

Warranty Information
For vehicles repaired under warranty use:
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 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.

Labor Operation

Description

Labor Time

Part Allowance

5031030

Drive Motor Generator Battery
Replacement

Use Published Labor
Operation Time

$400.00*

5031700

Add

Add

Drive Motor Generator Battery
Section Replacement

Use Published Labor
Operation Time

Road test – Data snapshot

Additional time to balance section

$250.00*

0.3 hr

1.0 hr

*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.

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