Service Bulletin

Bulletin No.:

19-NA-192

Date:

July, 2023

INFORMATION
Subject:

Information on Spark EV (BEV) High Voltage Battery Exchange Process

This bulletin replaces PIP5112S to reflect the revised TAC approval and battery pack ordering
process. Please discard PIP5112S.

Brand:

Model:

Chevrolet

Spark EV

Model Year:

VIN:

from

to

from

to

2014

2016

All

All

Engine:

Electric
Drive Unit:

EN0

1ET35
(RPO MME)

Involved Region or Country

North America

Information

The previous TAC part restriction for battery packs has been updated.

Recommendation/Instructions
Important: Service agents must comply with all
International, Federal, State, Provincial, and/or
Local laws applicable to the activities it performs
under this bulletin, including but not limited to
handling, deploying, preparing, classifying,
packaging, marking, labeling, and shipping
dangerous goods. In the event of a conflict between
the procedures set forth in this bulletin and the
laws that apply to your dealership, you must follow
those applicable laws.
Important: This technical service bulletin (TSB) can
only be completed by certified repair facilities who have
met all specific training, tool and equipment
requirements pertaining to the vehicle Brand and Model
serviced. Repairs must be performed by a technician
who has successfully completed the required training.
Please review all the information provided below prior
to contacting the General Motors Technical Assistance
Center (TAC) via Dealer Connect Messaging in the
U.S. In Canada, contact TAC at the 800 numbers
provided (refer to GM Canada Service Policies &
Procedures Manual) to request TAC approval.
Important: Prior to calling TAC, collect the required
information. Completing the diagnostics and obtaining
all required information will minimize downtime, multiple
contacts with TAC, misdiagnosis, or unnecessary
component replacement.

Copyright 2023 General Motors LLC. All Rights Reserved.

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.
• The GDS2 Session Log should include a
Vehicle Wide DTC Check with Module ID
Information, any relevant failure records,
Voltage screen data from the Hybrid Powertrain
Control Module 2 (HPCM 2) and cell voltage
data from the Battery Energy Control
Module (BECM).
• TAC will request that you e-mail the GDS2
Session Logs to them for immediate review.
• The latest version of PIP4902 provides
guidance on how to email GDS2 session logs
to TAC.

Page 2

July, 2023

Bulletin No.: 19-NA-192

•

3468543

2. Record the 16-digit BIN (Hybrid/EV Battery Pack
Identification Number), which is located on the right
side of the battery and can be seen without
removing the battery.
After the data is reviewed, TAC will authorize a
replacement Drive Motor Battery. The new battery will
be within 10% or greater capacity as the pack being
removed per the New Vehicle Limited Warranty.
Process
U.S Dealers Only: 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 shown
below under ‘Required Information’.
Canadian Dealers Only: After the dealer calls in and
works with TAC to create and/or update a case on a
battery replacement, TAC will use the case reference
number and order an exchange Drive Motor Battery
through York Electronics in Oshawa Canada.
Note: For Policy/Goodwill repairs, refer to information
provided in the Warranty Information section of this
bulletin. Dealers must obtain the necessary DM-CCSP
pre-approval prior to authorizing TAC to place an order.
The following information under ‘Required Information’
will need to be provided to TAC in order to complete the
order. Please have this information ready when calling.
Required Information for U.S. and Canada
• Dealer Name: ___________________
• Dealer Code: _________________________
• Shipping
Address:
______________________________________
• Contact At Dealership (include phone# and email
address): _____________________
• Hours of operation: ____________

Dealerships Preferred Dealer Delivery Time/Date
for Dealer Forklift Operator (Must be within 24
hours of the order time) Hours of
operation: ____________
• Does Dealership Need the Delivery Truck to have
a Lift Gate (if no forklift available): Y/N
• RO
#: ____________________________________
• Part # Being
Ordered:
____________________________________
• VIN #_________________________
• Model: ______
• Model Year_________________________
• TAC Case #_______________________
• Return Bin# (from battery)________________
• Customer
Complaint:
____________________________________
• Odometer
Reading: ____________________________
• 4–digit battery capacity number code or Ah
capacity reading
from GDS2_____________________
• Warranty Repair: Y/N
• Customer Pay Repair: Y/N
• Policy/Goodwill Repair (requires DM-CCSP
pre-approval in Canada): Y/N
Note: Please notify the 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.

Pack Removal Tips
Remove the battery assembly per SI procedures. Use
caution to properly disable high voltage as instructed in
SI. Only hybrid/EV trained technicians should remove
the battery pack.
Important: The Battery pack has two 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.
Remove any plastic shipping plugs or covers from the
new unit and install them on the Drive Motor Battery to
be returned.
Danger: The High Voltage Drive Motor Battery must
be protected when outside of the vehicle.
The battery should be placed in the shipping
container from the service battery as soon as
possible.

Bulletin No.: 19-NA-192

July, 2023

Pack Installation Tips
If working on a 2014 or 2015 Spark EV with the original
battery, refer to the following service bulletin for
additional instructions as only 2016 Spark EV batteries
are available to order:
• 17-NA-003: Information on Retrofitting 2014
Vehicles to Model Year 2016 High Voltage
Battery Pack
Programming and Set Up steps: (Please carefully
review steps 1-3):
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. Refer to Battery
Energy Control Module Programming and Setup
in SI.
2. Turn the ignition off, disconnect all devices from
the DLC, 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 to reset capacity for the new pack.
Using GDS2, select Control Functions, perform the
Hybrid / EV Pack Capacity Reset and then Battery
Capacity Relearn in the Hybrid Powertrain Control
Module 2 reset functions.
4. When SI procedures are complete, drive the
vehicle in Sport Mode with the vehicle in Low Gear
for approximately 8 km (5 mi). While safely
performing the 8 km (5 mi) repair confirmation,
drive the vehicle with some side to side and fore/aft
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 incorrect coolant could
result in internal battery or coolant heater damage.
5. Fully charge the vehicle before re-delivering it to
the customer.

Page 3

SHIPPING PREPARATION:

3943206

Take a digital picture of the shipping container depicting
the condition of the container as the shipping company
picks it up and retain it for the shop records.
It is important to package the Drive Motor Battery upon
return exactly as the service 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:

3943204

1. Banding Straps
2. Access Door

Page 4

July, 2023

Bulletin No.: 19-NA-192

Parts Retention and Returns (United
States Service Agents ONLY)
UNITED STATES SERVICE AGENTS ONLY:

3943203

3. Banding Straps
4. Access Door

3943205

5. Banding Straps

PACK STORAGE GUIDELINES:
1. Store the Drive Motor Battery flat.
2. Store the Drive Motor Battery in an environmentally
protected area (indoors).
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.

All exchanged Li-Ion drive motor batteries are required
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
pack. These charges are substantial.
Important: Li-Ion batteries are hazardous material.
GM requires that at least one person be hazmat
certified per servicing dealer. Additional resources for
hazardous material shipping can be found as part of
appendix G in the latest version of Service Bulletin
#99-00-89-019. A compromised (damaged) battery is
hazardous waste and must be discharged according to
SI procedures for damaged packs. All hazardous
materials and hazardous waste must be shipped in
accordance with all local, state, and federal laws.
Normal Exchange (Core) Return
For most pack replacements, contact CCA Logistics at:
[email protected] to arrange a pickup.
Ship to the address on the return Bill of Lading included
with the service pack.
DO NOT wait for the warranty claim to be processed
before returning the failed used drive motor battery.
This exchanged part is GMs material and is not claimed
under the warranty labor operation.
Place a copy of the repair order with the pack to be
returned. Failure to return a copy of the repair order
with the shipment may result in a debit. Attach the
completed return shipping tag to the cocoon.
DO NOT return the battery pack in any container other
than the container (cocoon) that the service battery was
delivered in. The removed unit must be returned
complete in the original exchange shipping container.
For questions about your order status, how to return
exchanged material, or to verify battery receipt contact:
GM Battery Service Center
c/o Spiers New Technologies
50 NE 42nd St
Oklahoma City, Oklahoma 73105–2201
1-833-33 GM BSC (1-833-334-6272)

CANADIAN SERVICE AGENTS ONLY:
Canadian Failed Battery Returns:
All lithium-ion batteries and battery sections that are
removed from the vehicle need to be returned to the
appropriate core return centre. Refer to GM
GlobalConnect for the latest GM Canada Parts Bulletin
relating to procedures for return of EV Batteries or
Sections. This can be found under Parts Bulletins &
Resources located in the application section of the
Parts Department page.
Canadian Dealers DO NOT return batteries to an
Electronic Service Center (ESC) or to the Warranty
Parts Center (WPC).

Bulletin No.: 19-NA-192

July, 2023

Page 5

Note: If the battery or sections are not returned within
30 days of receipt of the exchange component, the
entire transaction will be debited and the dealer will
also be charged the value of a replacement battery.

Parts Information
Note: The high voltage battery part number should not
be entered on the warranty claim because it is on part
exchange.
Miscellaneous parts such as coolant should be added
in the Parts field and not included in the Net Item field of
the warranty claim.

Warranty Information
For warranty repairs made under coverage code V
(Voltec/EV) or E (Emissions), refer to Warranty
Administration Service Bulletin #18-NA-180 for the
latest Labor Operation / Description / Labor Time / Net
Admin Allowance.

For Lithium-Ion Battery Replacements under Policy:
Policy Information (United States)
Note: For high voltage batteries replaced under Policy, the
following guidelines are in effect as of September 30, 2020:
1. If the dealer wants to extend Policy assistance in the
repair costs, the dealer must follow guidelines listed in
the latest version of Service Bulletin 11-00-89-005 and
run the Policy Evaluation Tool entering the labor,
miscellaneous parts, and all net items at warranty rates.
2. High voltage batteries and sections replaced under Policy
are provided at no cost* to the dealer through the GM
Battery Service Center (BSC) exchange program. Dealer
must inform the BSC at the time of ordering that the
repair is being made under Policy. Do not include the cost
of a battery or section when running the Policy Evaluation
Tool. Do not enter the battery or section part number or
cost on the submitted transaction.
3. Refer to Service Bulletin #18-NA-180 for the eligible
handling allowance for the battery or section. This
amount is to be entered in the Net/Admin Allowance field
of the submitted transaction. As a “Net” item, this amount
should also be included when running the Policy
Evaluation Tool.
4. Miscellaneous items such as coolant should be entered
in the Parts field and not in the Net Amount of the
submitted transaction.
*Dealer is not billed for an exchange component unless the
defective part is not returned within the prescribed time period
(30 days), TAC pre-approval was not obtained, or if the BSC is
not notified at the time of order that the repair is being made
under Policy. These charges are not eligible for
reimbursement.

Policy/Goodwill Information (Canada)
Note: For batteries replaced under Policy, the following
guidelines are in effect as of September 11, 2020:
1. All Policy/Goodwill repairs involving material ordered
through York Electronics (via TAC) must have
pre-approval from the District Manager (DM-CCSP).
Failure to obtain approval prior to ordering may result in
the full cost of the battery being billed to the dealer for
repair outside of warranty coverage. These charges are
substantial and are not reimbursable. The Dealer must
have pre-approval via email or other type of
communication involving the District Manager
(DMCCSP).
2. Attach a copy of the approval from District Manager
(DM-CCSP) to the job card.

Page 6

July, 2023

Bulletin No.: 19-NA-192

For Lithium-Ion Battery Replacements as Customer-Pay:
Customer Pay Information (United States)

Customer Pay Information (Canada)

1. The GM BSC will provide a quote for the part ordered, or
for the best part currently available for the repair.
Refurbished batteries may not always be in stock, and an
appropriate substitute may be required as determined by
the GM BSC based on current availability.
2. The GM BSC will require full payment for the part up front
before shipment.
3. Core returns (including shipping) are accepted free of
charge by the GM BSC when originating from a repair
made at a GM dealer. Contact XPO for pickup using the
same instructions as core returns listed above.

1. York Electronics will provide a quote for the part ordered,
or for the best part currently available for the repair.
Refurbished batteries may not always be in stock, and an
appropriate substitute may be required as determined by
York Electronics based on current availability.
2. Payment to York Electronics is required within 30 days
upon receipt of the battery, failure to pay within these
terms will result in charge by GM Customer Care &
Aftersales (GMCCA) to your Service Agent open account
at the Service Agent List Price. These charges are
non-refundable.
3. Core returns: Refer to GM GlobalConnect for the latest
GM Parts Bulletin relating to procedures for return of EV
Batteries or Sections. This can be found under Parts
Bulletins & Resources located in the application section
of the Parts Department page. Canadian Dealers DO
NOT return batteries to the ESC or to the WPC. If the
battery is not returned within 30 days of receipt of the
exchange component, the dealer will be charged the
value of a replacement battery.

Version

6

Modified

Released August 27, 2019
Revised September 11, 2020 – Updated the information under Parts Retention and
Returns, added the Parts Information section and updated the Warranty Information.
Revised October 13, 2020 – Updated the last line under Required Information for U.S.
and Canada and updated the Parts Information and Warranty Information.
Revised April 25, 2022 – Corrected Propulsion RPO, updated Information section with
statement and removed all other content.
Revised April 28, 2022 – Reverted bulletin to previous information and removed Bulletin
reference 16-NA-142 from under Pack Installation Tips.
Revised July 17, 2023 – Added the first two Important statements under
Recommendation/Instructions and updated e-mail address under Normal Exchange
(Core) Return section.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.

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