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Home >> Chevrolet >> 2013 >> Volt L4-1.4L Elect >> Repair and Diagnosis >> Hybrid Drive Systems >> Battery System, Hybrid Drive >> Service and Repair >> Procedures

Procedures




Drive Motor Battery Replacement and Shipping Preparation (Volt)

Special Tools

* EL 49976 - Battery Pack Lifting Fixture

* 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 includes the following steps:


* 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 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 if you have any questions.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.

2. Remove the rear heat shields. Refer to Exhaust Pipe Heat Shield Replacement (Rear) Exhaust Pipe Heat Shield Replacement (Rear)Exhaust Pipe Heat Shield Replacement (Front) Exhaust Pipe Heat Shield Replacement (Front)Exhaust Pipe Heat Shield Replacement (Center) Exhaust Pipe Heat Shield Replacement (Center).

Note: Not necessary to remove the underbody battery shield.

3. Remove the right underbody air deflectors. Refer to Underbody Front Air Deflector Replacement - Right Side .

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




5. Remove the drain plug (1) only if preparing the battery for refurbishment or internal component repair.

6. Collect any fluid present in the drain pan and if no fluid is present, insert a clean white cloth or cotton swab through the drain plug opening, looking for any evidence of coolant residue.

Note: Document 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 F118 (1).

* Interlock Loop Connectors X6, X7 (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.





Note: Do not remove the underbody air deflector from the battery. This deflector should remain with the failed battery and returned to the refurbishment center. The replacement battery will be shipped with the underbody air deflector already installed.

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).




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 container 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 the drive motor generator battery 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. If the drive motor generator battery is being returned, prepare the drive motor generator battery for safe shipping by performing the following:

Note: As part of the battery removal process, all coolant should be drained from the battery pack.

* Install coolant plugs (2) in the 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: The MSD lever should remain with the vehicle and not be returned with the battery assembly.

* Install the S15 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 22770856) can be ordered if they are needed.

Note: The failed 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 failed battery and placed in the shipping container. 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.

* Install the High Voltage Connector Cover. The high voltage connector cover can be removed from the service battery and installed on the returned battery. If the service battery assembly did not come with a high voltage connector cover, additional covers can be ordered by calling 1-800 GM TOOLS. Reference tool # EL-50209 when placing your order.

Installation Procedure




1. Using the EL 49976 - lifting fixture, in conjunction with a suitable lift table, raise the generator drive motor battery (1) 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 F118 (1).

* Interlock Loop Connectors X6, X7 (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 (Rear) Exhaust Pipe Heat Shield Replacement (Rear)Exhaust Pipe Heat Shield Replacement (Front) Exhaust Pipe Heat Shield Replacement (Front)Exhaust Pipe Heat Shield Replacement (Center) Exhaust Pipe Heat Shield Replacement (Center).

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. Check the battery pack cooling system for leaks. Refer to Hybrid Cooling System Leak Test Hybrid Cooling System Leak Test.

12. Clear the secured high voltage DTC's. Refer to Clear Secured High Voltage DTCs Reading and Clearing Diagnostic Trouble Codes.

13. Reset the Hybrid/EV battery pack data. Refer to Hybrid/EV Battery Pack Data Reset Hybrid/EV Battery Pack Data Reset.

14. 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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