Bulletin No.: PIP5112S
Published date: 06/10/2019

Preliminary Information
PIP5112S Spark EV (BEV) High Voltage Battery Exchange Process
Models
Brand:
Chevrolet

Model:
Spark EV

Model Years:
2014 - 2016

VIN:
from
All

to
All

Engine:
ENO

Transmissions:
MME

Supersession Statement
This PI was superseded to update ordering process. Please discard PIP5112R.

Condition / Concern
As part of our ongoing quality improvement process e ective as of 08/06/2014, the Drive Motor Battery for the
2014 - 2016 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). 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 advise dealer to call the Battery Service Center (BSC) to order the Drive Motor Battery.
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.
- 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 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 speci cation 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 BSC 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 Battery Service Center (BSC). 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. 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 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.

Recommendations / Instructions
IMPORTANT: Only have a certi ed 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 Identi cation 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 nd the BIN by installing the MDI and using GDS2. Access the
BECM Module Information and look under the identi cation information section and the sixteen digit number will
be listed under the GDS2 parameter:
Hybrid/EV Battery Identi cation 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 Identi cation 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 identi ed 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 Battery Service Center (BSC) in order to have it shipped to your dealership.

Dealers are now asked to order packs and sections directly from the GM Battery Service Center by calling 1833-33 GM BSC (1-833-334-6272).
This is the information that the dealer will need to Provide Speirs when calling to order a Battery.
Dealer Name: ___________________
Dealer Code: _________________________
Shipping Address: ______________________________________
Contact At Dealership (include phone#): _____________________
Dealerships Preferred Dealer Delivery Time/Date for Dealer Forklift Operator (Must be
within 24 hours of the order time) Hours of operation: ____________
RO #: ____________________________________
Part #:____________________________________
Battery Type: _______________________________
VIN #_________________________
TAC Case #_______________________
BIN _________________________
Customer Complaint: ____________________________________
Odometer Reading: ____________________________
Standard of Service is 2 Day Freight– Is customer requesting next day delivery?: _______
Banding Kit Needed? __No __Yes
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, ll 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
aero panels upon nal 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 o , 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 o 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 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 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 Battery Service Center (BSC).
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 o cial 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 speci cation 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. Inspect Shipping Crate for any damage prior to inserting the Drive Motor Battery, if any damage is found
contact TAC
8. Place the Drive Motor Battery into the shipping container and attach the completed return shipping tag to the
Drive Motor Battery.
9. Take a digital picture of the shipping container depicting condition of container as the shipping company picks
it up and retain it for the shop records.

10. 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 obtained if requested when placing the battery order through TAC.

1) Banding Straps
2) Access Door

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:
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 GMP2013081.

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 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. Inspect Shipping Crate for any damage prior to inserting the Drive Motor Battery, if any damage is found

contact TAC
8. Place the Drive Motor Battery on the cradle into the shipping container.
9. 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.
10. 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.
11. Take a digital picture of the shipping container depicting condition of container as the shipping company picks
it up and retain it for the shop records.

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 Battery Service Center (BSC) or to the WPC.
Please Refer to as needed
16-NA-142 Retro t of 2015 Vehicles to Model Year 2016 High Voltage Battery Pack
17-NA-003 Information on Retro tting 2014 Vehicles to Model Year 2016 High Voltage Battery Pack

Parts Information
COMPONENT MODEL
CODE
YEAR

PART NAME

PART
NUMBER

QTY

A4

2014

HV Drive Motor Battery (use 17-NA-003 for all parts
needed to install)

24287480

1

A4

2015

HV Drive Motor Battery

24287479

1

A4

2016

HV Drive Motor Battery (Can Back service 2014 and 2015)

24287480

1

Warranty Information
For vehicles repaired under the EV coverage, use the following labor operation. Reference
the Applicable Warranties section of Investigate Vehicle History (IVH) for coverage
information.
Labor
Operation

Description

Labor Time

Net Admin
Allowance

5031030

Drive Motor Battery Replacement

Use
Published
Labor
Operation
Time

$400.00

Add

Administrative Allowance

N/A

$20

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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