Volt

Drive Motor Battery Replacement and Shipping Preparation

Special Tool

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

For equivalent regional tools, refer to Special Tools .

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.

Danger: The Volt Battery Pack will utilise 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 Centre (1-877-446-8227) if you have any questions.

1. Disable the high-voltage system. Refer to High Voltage Disabling .
2. Remove the rear heat shields. Refer to Exhaust Pipe Heat Shield Replacement : Rear  → Center  → Front .
3. Remove the right underbody air deflectors. Refer to Underbody Front Air Deflector Replacement - Right Side .

Note: Not necessary to remove the underbody battery shield.

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



5. Using a drain pan to collect any fluid, remove the drain plug (1) and drain the drive motor battery of fluid.

Note: Document the colour of the fluid and the quantity of fluid drained. Replace the drain plug with a NEW drain plug.




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



7. Disconnect the following from the drive motor battery:

•	Body Harness Connector X5 (1).

•	Interlock Loop Connectors X3, X4 (2).

•	Connectors X1 and X2 (3).




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



10. Remove connectors X4 and X5 (1).



11. Remove the 300 volt cable connector fastener (1).



12. Remove the earth strap fasteners (1), from the body side.



13. 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).



14. Remove the battery tray fasteners (1) and (2).
15. Remove the drive motor generator battery and the EL-49976 battery lifting fixture from the lift table and set aside.
16. Remove the replacement drive motor generator battery and the replacement EL-49976 battery lifting fixture from the container and mount to the lift table.
17. 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.
18. Ensure that tape covers the manual disconnect terminals on the drive motor generator battery.
19. If the drive motor generator battery is being returned, prepare the drive motor generator battery for safe shipping by performing the following:

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

•	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 22770856) 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 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.

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.

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 in the Preface section.




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



3. Install the earth strap fasteners (1) and tighten to 9 N·m (80 lb in).



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



5. Connect the 300 V Cable (3) to the drive motor generator battery and tighten bolt (2) to 8 N·m (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 : Rear  → Center  → Front .
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 .
11. Check the battery pack cooling system for leaks. Refer to Hybrid Cooling System Leak Test .
12. Clear the secured high voltage DTC's. Refer to Clear Secured High-Voltage DTCs .
13. Reset the Hybrid/EV battery pack data. Refer to Hybrid/EV Battery Pack Data Reset .
14. Program the battery energy control module. Refer to Electronic Brake Control Module Programming and Setup .
15. Perform the Hybrid/EV battery pack capacity learn procedure. Refer to Hybrid/EV Battery Pack Capacity Learn .