Bulletin No.: PIC6127K
Published date: 08/29/2018

Preliminary Information
PIC6127K (Volt) High Voltage Drive Motor Battery TAC Restriction
and Exchange Program
Models
Brand:
Chevrolet

Model:
Volt

Model Years:
2016 - 2019

VIN:
from
All

to
All

Engine:
L3A

Transmissions:
MKV

Supersession Statement
This PI was superseded to remove battery sections o restriction. Please discard PIC6127J.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition / Concern
As part of GM’s ongoing quality improvement process, the High Voltage Drive Motor Battery
Pack is currently on restriction through the GM Technical Assistance Center (TAC). Other
internal battery pack components not containing Lithium-Ion material can be ordered
through CCA without restriction. If a battery section is required, please refer to the current
version of bulletin: 18-NA-236
Use SI procedures to determine whether a pack is needed. GM TAC can provide guidance to
repair or replace. Warranty claims will be audited to ensure the minimum number of parts
were replaced to repair the vehicle.
NOTE: Please review all of the information provided below prior to contacting the GM 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.
Once GM TAC has authorized a battery pack, dealers are now asked to order packs directly
from the GM Battery Service Center by calling 1-833-33 GM BSC (1-833-334-6272). Please
note the information required at the time of ordering is contained under Parts Information
later in this document. Batteries are on exchange, and new or refurbished material will be
provided at or above the capacity of the battery being removed.
Material will arrive within 48 hours of ordering. For any delays or backorders, please contact
the GM Battery Service Center by calling 1-833-33 GM BSC (1-833-334-6272) for the current
status of your order.

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 di erent 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 speci c drive motor battery exchange bulletin in eSI for the vehicle
being repaired.
Note: Failure to return the battery 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 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.

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. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling. Refer to eSI.
2. Remove the Drive Motor Battery from the vehicle as outlined in Drive Motor Generator Battery
Replacement in eSI.
3. Tighten any fasteners that were loosened or removed during Drive Motor Battery removal to the original
torque speci cation.
4. Remove any plastic shipping plugs or covers from the new unit and install them on the Drive Motor Battery
to be returned.
5. 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 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”.
2. 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 o cial
WPC Request.
3. 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

4. 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.
5. 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.
6. 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 battery 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 eld.
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) Certi ed 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.
Battery components received from the BSC/ESC should NOT be entered on the transaction. Dealers are not billed
for the component unless the core is not returned within the required time period.

CANADIAN SERVICE AGENTS ONLY
All Volt batteries must be returned to the appropriate core return center 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 transaction as
well as assessment of an environmental fee for the value of the failed pack. This environmental fee is substantial
($10,000) and will only be assessed if the battery is not returned.
For dealers in Canada, the return of failed batteries will be handled through the existing core return process.

(Type 4 return)

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 during Drive Motor Battery removal to the original
torque speci cation.
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 “BATTERY PRODUCT FEEDBACK FORM” (which was included in the container containing the
new battery) inside the cocoon with the failed battery. Dealers need to place a new envelope inside the battery
cocoon with completed Volt 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 cocoon.

Canadian Shipping Instructions:
Canadian Dealers should follow the steps below to return a failed battery:
1. Submit a type 4 core return for the battery. A core return tag along with a core return application will be
generated at your servicing PDC and sent to you.
2. Place the core return tag on the outside of the battery container (cocoon).
3. Complete the required return hazardous goods shipping paperwork (302C form)
4. Leave the labeled container (cocoon) along with the necessary shipping documents in the area within your
dealership which you would normally use for your material/core returns. The DDS carrier will pick up this battery
core along with your normal returns. If your dealership is not serviced by a DDS carrier you will need to return
this battery via LTL (similar to how you would return other parts).
5. Canadian Dealers do NOT return batteries to the ESC or to the WPC.

Recommendations / Instructions
Please have a certi ed Volt technician follow the diagnostic procedures below prior to contacting TAC and the
Battery Service Center.
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 with approval for the dealer to order
Lithium Ion material directly from the GM Battery Service Center (BSC).
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 identi cation number (BIN) and the 4 digit battery capacity number will need to be
supplied to the BSC 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 identi cation tag that is located on the right side of the battery. Locate the tag and
record the 16 digit battery identi cation 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 nd the BIN by
installing the MDI and using GDS 2. Access the Battery Energy Control Module and look under the identi cation
information section and the sixteen digit number will be listed under the parameter: Hybrid/EV Battery Pack
Identi cation Number.

7. You will have to advise the BSC 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 ll
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 ll
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 Con guration/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 o the coolant system.
11. 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 xture (GM Special Tool EL49976.) This lifting xture will be attached to the used battery and placed in the shipping cocoon. Each new
service battery will come with a battery assembly lifting xture for use during installation. You will keep this
xture 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 at.
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
Be prepared to provide the Battery Service Center with the following information:
Warranty (W) or Customer P ay (CP):
Note: Carefully review V oltec and PZ EV Emission warranty coverage in GWM.
Dealer Name:
Dealer BAC Code:
Shipping Address:
Contact at Dealership (include phone#):
Preferred Delivery Time/Date for Dealer F orklift Operator (Must be within 48 hours of
the order time not including week end)
Hours of operation:
Do you need the delivery truck to have lift gate: Y / N
Vehicle Mak e:
Vehicle Model:
Model Year:
RO #:
VIN #:
Approved TAC Case # (required for T AC restricted parts):
DTCs and Customer Complaint:
Note: If no DTC S are present or repa ir is for accident repair or EV range, T AC approval
is also required.
Odometer Reading:
Causal Part # Ordered (provided by dealer):
Causal Return BIN # (from GDS2 BECM):
Capacity Code (from GDS2 HPCM2 V oltage da ta):

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*

Add

Road test – Data snapshot

0.3 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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