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Home >> Chevrolet >> 2012 >> Volt L4-1.4L Elect >> Repair and Diagnosis >> Hybrid Drive Systems >> Battery System, Hybrid Drive >> Service and Repair >> Removal and Replacement >> Drive Motor Battery Replacement

Drive Motor Battery Replacement




Drive Motor Battery Replacement

Special Tool
1. EL 49976 - Battery Pack Lifting Fixture
2. EL 50209 - Battery Terminal Covers

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

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:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* 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:


* Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

* Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.


- Visually and functionally inspect the gloves before use.

- Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.


Failure to follow the procedures exactly as written may result in serious injury or death.


Danger: The Volt Battery Pack will utilize an exchange program. Please consult the most recent revision of bulletin/PI #PIP4841, available in Service Information (SI), for a list of approved Volt Battery Pack service procedures. Components that may be removed and serviced without exchanging the complete battery pack are identified in the bulletin/PI. Please contact the GM Technical Assistance Center (1-877-446-8227) if you have any questions.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.
2. Drain the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling Drive Motor Battery Cooling System Draining and Filling.
3. Remove the rear heat shields. Refer to Exhaust Pipe Heat Shield Replacement (Front) Exhaust Pipe Heat Shield Replacement (Front)Exhaust Pipe Heat Shield Replacement (Center) Exhaust Pipe Heat Shield Replacement (Center)Exhaust Pipe Heat Shield Replacement (Rear) Exhaust Pipe Heat Shield Replacement (Rear).
4. Remove the right underbody air deflector. Refer to Underbody Front Air Deflector Replacement - Right Side .
Note: Not necessary to remove the underbody battery shield.

5. Remove the drive motor generator radiator surge tank cap.




6. Using a drain pan to collect any fluid, remove the drain plug (1) and drain the drive motor battery of any fluid.
Note: Determine if the battery cells have leaked by documenting the color of the fluid and the quantity of fluid drained. Replace the drain plug with a NEW drain plug.




7. Using a drain pan to collect any coolant, remove the metal coolant pipe retainers (1) and disconnect the inlet and outlet coolant pipes (2).




8. Disconnect the following from the drive motor battery:

* Body Harness Connector X5 (1).
* Interlock Loop Connectors X3, X4 (2).
* Connectors X1 and X2 (3).




9. Remove the 300V positive and negative cable connector mounting bolt (2).
10. Remove the 300V positive and negative cable connector (3).




11. Remove connectors X4 and X5 (1).




12. Remove the 300-Volt cable connector fastener (1).




13. Remove the ground strap fasteners (1), from the body side.





Caution: When removing, reinstalling or transporting the hybrid/EV battery pack, ensure the correct usage of EL-49976. Once removed from the vehicle, do not remove the battery pack from the EL-49976 lifting fixture. Otherwise damage to the battery pack may result.

Caution: Use the EL-49976 Lifting Fixture that comes with the replacement battery, to install the NEW generator battery. Never remove the generator battery EL-49976 Lifting Fixture without all fasteners secured to the generator battery. Damage to the battery may result.

14. Support the battery (1) using the EL 49976 - lifting fixture , in conjunction with a suitable lift table. The battery mass is approximately 204 kg (450 lbs).





Caution: Once removed from the vehicle, do not remove the generator battery from the EL-49976 lifting fixture. Damage to the battery may result.

15. Remove the battery tray fasteners (1) and (2).
16. Remove the drive motor generator battery and the EL-49976 - battery lifting fixture from the lift table and set aside.
17. Remove the replacement drive motor generator battery and the replacement EL-49976 - battery lifting fixture from the carton and mount to the lift table.
18. If the drive motor generator battery is to be out of the vehicle for an extended period of time, place in a safe location with the appropriate safety cones and protocols. Install EL50209 - protective terminal
covers on connection points.
19. Ensure that tape covers the manual disconnect terminals on the drive motor generator battery.
20. Place the old generator drive motor battery and the EL-49976 - battery lifting fixture in the carton for return.

Installation Procedure




1. Using the EL 49976 - lifting fixture , in conjunction with a suitable lift table, raise the generator drive motor battery to the vehicle.





Caution: Refer to Fastener Caution Fastener Caution.

2. Tighten the battery tray fasteners (1) to 58 Nm (43 lb ft) and tighten the battery tray fasteners (2) to 22 Nm (16 lb ft).




3. Install the ground strap fasteners (1) and tighten to 9 Nm (80 lb in).




4. Install the X4 and X5 connectors (1).




5. Connect the 300V Cable (3) to the drive motor generator battery and tighten bolt (2) to 8 Nm (71 lb in).




6. Connect the following to the drive motor generator battery:

* Body Harness Connector X5 (1).
* Interlock Loop Connectors X3, X4 (2).
* Connectors X1 and X2 (3).




7. Connect the inlet and outlet coolant pipes (2) and install the metal coolant pipe retainers (1).
8. Install the rear heat shields. Refer to Exhaust Pipe Heat Shield Replacement (Front) Exhaust Pipe Heat Shield Replacement (Front)Exhaust Pipe Heat Shield Replacement (Center) Exhaust Pipe Heat Shield Replacement (Center)Exhaust Pipe Heat Shield Replacement (Rear) Exhaust Pipe Heat Shield Replacement (Rear).
9. Install the right underbody air deflectors. Refer to Underbody Front Air Deflector Replacement - Right Side .
10. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.
11. Fill the drive motor battery cooling system. Refer to Drive Motor Battery Cooling System Draining and Filling Drive Motor Battery Cooling System Draining and Filling.
12. Perform a hybrid battery pack coolant passage leak test. Refer to Hybrid Battery Pack Coolant Passage Leak Test Hybrid Battery Pack Coolant Passage Leak Test.
13. Clear the secured high voltage DTC's. Refer to Clear Secured High Voltage DTCs Reading and Clearing Diagnostic Trouble Codes.
14. Reset the Hybrid/EV battery pack data. Refer to Hybrid/EV Battery Pack Data Reset Hybrid/EV Battery Pack Data Reset.
15. Perform the Hybrid/EV battery pack capacity learn procedure. Refer to Hybrid/EV Battery Pack Capacity Learn Hybrid/EV Battery Pack Capacity Learn.

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