Product Safety Recall N212343881 High Voltage Battery May Melt or Burn – 2017-2019 Chevrolet Bolt EV

Condition

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2017-2019 model year Chevrolet Bolt EV vehicles. The high voltage batteries in these vehicles may pose a risk of fire when charged to full, or very close to full, capacity.

 

Correction

Dealers will replace the lithium-ion battery pack in the vehicle.

 


Frequently Asked Questions (FAQs) for Safety Recall N212343881 High Voltage
Battery May Melt or Burn

 

These questions and answers are being provided to help GM dealers respond to inquiries from involved vehicle owners about the Safety Recall identified above.

 

Q1) Which vehicles are involved?

All 2017-2019MY Chevrolet Bolt EV vehicles

 

Q2) What is the issue or condition?

The high voltage batteries in these vehicles may pose a risk of fire when charged to full, or very close to full, capacity.

 

Q3) What symptoms may be experienced? What warning signs may be associated with the issue or condition described?

The battery may emit smoke or heat, and the condition may melt or damage the battery and other vehicle components.

 

Q4) What is the remedy/repair?

Dealers will replace the lithium ion battery modules in the recalled vehicles with new lithium ion battery modules as parts become available.

 

Q5) What is the safety risk?

If the batteries in certain vehicles within this population are charged to full capacity, or very close to full capacity, the batteries may pose a risk of fire.

 

Q6) Does the customer have to pay for this remedy/repair?

No, this repair will be done at no cost to the customer.

 

Q7) Is the remedy/repair available now?

Certain Chevy Bolt EV customers can now contact their dealer to schedule an appointment for their repair.

 

Q8) What should customers do until recall repairs can be completed? Are there any special instructions?

Yes, until the lithium ion battery modules are replaced (N212343881), OR the vehicle receives the advanced diagnostic software package, customers should take the following interim steps:

  1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
  1. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
  1. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.

 

Q9) How can customers check to see if their vehicle is involved in this field action?

Customers who own a vehicle involved in the field action will be notified by mail by General Motors, but they may also check their Vehicle Identification Number (VIN) for field actions in GM Owner Center at https://my.gm.com/recalls or via NHTSA’s website at https://vinrcl.safercar.gov/vin/.

 

Q10) If customers are concerned, can they get a rental car or courtesy transportation?

Courtesy transportation is available for customers whose vehicles are involved in this safety recall.

 

Q11) Where should customers go to get more information on the recall?

Customers should visit www.chevy.com/boltevrecall or contact the Chevrolet EV Concierge 1-833-EVCHEVY.  Hours of operation are Monday through Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM to 9:00 PM ET or contact their preferred Chevrolet EV dealer.

 

Q12) How long should a customer expect to wait for replacement battery modules?

We will provide replacement battery modules to dealers as quickly as possible. We continue to work with our supplier to expedite capacity for battery modules under this recall.

 


 


Product Safety Recall
N212343881 High Voltage Battery May Melt or Burn
Copyright 2022 General Motors. All Rights Reserved. Page 1 of 48
Release Date:
April 2022
Revision:
04
Revision Description:
This bulletin has been revised to update the Parts Information. The high voltage battery part numbers have been removed from the parts table. The battery service center will provide the appropriate high voltage battery part number based on the requested VIN. The VIN on the Bill of Lading needs to be verified to exactly match the VIN of the vehicle. Please discard all previous copies of bulletin N212343881.
Attention:
It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.
Vehicles involved in this recall were placed on stop delivery in safety recall N212343880 on July 23, 2021.
All involved vehicles that are in dealer inventory must be held and not delivered to customers, dealer traded, used for loaners, or used for demonstration purposes until the repair contained in this bulletin has been performed on the vehicle.
This safety recall bulletin contains the final remedy for VINs originally released in safety recall N212343880. N212343880 contains an interim service procedure, not the final remedy. When the final remedy is available for a specific vehicle, that vehicle will be moved from the population of N212343880 into the population of this bulletin N212343881 and will be marked “Open” in IVH.
Danger: Carefully read this bulletin before beginning the remedy procedure. This bulletin contains important legal and safety requirements that must be followed in order to safely replace the vehicle’s high voltage battery in compliance with applicable federal, state, provincial, and local laws. To avoid injury or death, use of a forklift is required to safely load and unload crated batteries into and out of delivery trucks. Failure to carefully follow the procedures in this bulletin may result in serious injury or death.
IMPORTANT: The warranty information section of this bulletin has information regarding the required documentation of the replacement high voltage battery identification number in the warranty claim.
IMPORTANT: US dealers should only use the “Bolt EV Battery Safety Recalls” app in Global Connect to arrange a high voltage battery core return. DO NOT CALL CCA Logistics or XPO directly.
IMPORTANT: The part number labels on the service high voltage battery are the production part number and may be different from the service part number.
Dealer Forklift Requirements: At least one (1) 3,000-pound (1,361kg) forklift within the Chevrolet dealership premises along with ample space to maneuver the Forklift between service bays. The Forklift must have forks that are a minimum length of 48 inches (122cm); 60 inches (152cm) is preferred, or fork extensions available to meet this requirement. In addition, at least one trained employee that is forklift certified in accordance with local, state, provincial, and federal regulations is required.
This recall must only be completed by Chevrolet EV certified dealers who have met all Bolt recall-specific training, tool and equipment requirements. Repairs must be performed by a technician who has successfully completed the required training.
For Markets other than US and Canada, Refer to Field Action bulletin N212343882.
Product Safety Recall
N212343881 High Voltage Battery May Melt or Burn
Page 2 of 48
Table of Contents
Content
Page Number
Vehicle Preparation Before Entering the Repair Garage
2
Adjusting (Reducing) the SOC
2-3
Storage Guidelines
3-4
Parts Ordering Information
4
Parts Retention and Return
5-6
Warranty Information
6-7
Tool Specifications
7-8
Personal Protective Equipment
8
High Voltage Battery Replacement Service Procedure
8-9
Unloading Service High Voltage Battery from crate using FORKLIFT
14-20
Programming
20-25
Removed Battery Return Preparation
25-32
Engine Hoist and Pallet Jack Method for Uncrating/Crating
33-39
Final Shipping Preparation
39-46
Make
Model
Model Year
RPO
Description
From
To
Chevrolet
Bolt EV
2017
2019
Involved vehicles are marked “Open” on the Investigate Vehicle History screen in GM Global Warranty Management system. This site should always be checked to confirm vehicle involvement prior to beginning any required inspections and/or repairs.
Condition
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2017-2019 model year Chevrolet Bolt EV vehicles. The high voltage batteries in these vehicles may pose a risk of fire when charged to full, or very close to full, capacity.
Correction
Dealers will replace the lithium-ion battery pack in the vehicle.
Vehicle Preparation Before Entering the Repair Garage
The vehicle must have a minimum of 24 hours between the last high voltage battery charge (plug in charging) and the beginning of the high voltage battery removal. In addition, the high voltage battery must be at a state of charge (SOC) less than 90%.
Once the vehicle is received for service it should not be plug-in charged until the replacement high voltage battery has been installed. Place masking tape over the charge receptacle door to prevent unintended charging. The tape should not be removed until after the replacement high voltage battery has been installed.
IMPORTANT: Vehicles charged within the last 24 hours should be parked outside of the dealership until it has been 24 hours since the last charging event.
Perform the following steps BEFORE the high voltage battery removal.
1. Request the last plug in charge time from the customer.
• If the customer states the time of the last plug in charge is less than 24 hours, park vehicle outside until at least 24 hours has occurred from the last plug in charge time provided by the customer. The total time between the last plug in charge and the battery removal must be at least 24 hours.
• If unsure or not able obtain the last charge time, park vehicle outside until at least 24 hours reached.
Product Safety Recall
N212343881 High Voltage Battery May Melt or Burn
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Adjusting (Reducing) the SOC
5905973
Important: Verify the vehicle SOC is less than 90%. This can be determined by looking at the bars on the power level indicator. If two or more empty bars (not showing green) are displayed, the SOC is at an acceptable level. If the power level indicator shows an SOC of greater than 90%, follow the bulleted procedure below until SOC is less than 90%.
Caution: During this procedure, a puddle of water may form around the vehicle from HVAC system drainage. Use care to prevent any slip/fall conditions.
Note: Each hour of operation will reduce SOC by about 10%. Left unattended, the vehicle will automatically turn OFF after 2 hours. This procedure must be performed in a secure location because the vehicle is in a drivable condition. Take proper steps to ensure no unauthorized drivers have access to the vehicle.
• Vehicle in PARK, Vehicle ON.
Headlamps Low Beam: ON.
• Temp Control: Hi (Max Heat High) (note: windows should be down).
• Distribution: MAX Defrost (Engages AC Compressor).
• Fan Speed: High (8).
• Select: Fresh Air (Not recirc).
• Select: Heat & A/C .
• If equipped, turn heated seats to hi position.
• Verify SOC after 60 minutes. If the SOC is less than 90%, proceed with the steps below. If the SOC is above 90%, allow additional power burn off time.
• When the SOC adjustment is completed return the HVAC controls to 72 Deg. AUTO, Set the headlamp control to AUTO.
Parts Information
Quantity
Part Name
Part No.
1
BATTERY- HIGH VLTG
*
1** (if required)
HOSE HIGH VLTG (2017 only)
42557402
2
COOLANT ENGINE (50/50 Mix)
12378390 US 10953456 CA
* See “Parts Ordering Information” section below. The battery service center will provide the appropriate high voltage battery part number based on the requested VIN. The VIN on the Bill of Lading needs to be verified to exactly match the VIN of the vehicle. The part number labels on the service high voltage battery are the production part number and may be different from the service part number.
** Order through CCA.
Storage Guidelines for Containerized High Voltage Batteries
• Store the High Voltage Battery and shipping crate flat.
Product Safety Recall
N212343881 High Voltage Battery May Melt or Burn
Page 4 of 48
• Store the High Voltage Battery and shipping crate in an environmentally protected area (indoors).
• Protect the High Voltage Battery and shipping crate from exposure to liquids, including rain and snow.
• Protect the High Voltage Battery and shipping crate from physical damage.
Parts Ordering Information
For Markets other than US and Canada, refer to Field Action bulletin N212343882.
For US Dealers:
In order to simplify the ordering process for high voltage batteries necessary to perform repairs under THIS RECALL, the high voltage battery ordering process requiring authorization from the Technical Assistance Center (TAC) is not required. Battery ordering will be completed using the “Bolt EV Battery Safety Recalls” app in GlobalConnect. The application can be located in either the “App Center” or “Parts Department” in GlobalConnect. All other high voltage battery orders NOT related to the recall must continue to be authorized through Technical Assistance. Once you locate and enter the app you will be connected directly to the Spiers New Technologies (SNT) ordering portal. At this point simply click the “Create New Recall Order” to begin the process to order a high voltage battery. Before visiting the SNT ordering portal, please have all required information available (shown below).
Note that in addition to order placement, this app is also used to arrange for the high voltage battery core return. 5903430
US dealers will get their replacement packaging materials through the SNT app in Global Connect (same app as they use to order and return the high voltage battery).
For Canadian Dealers:
High voltage batteries may be ordered from York Electronics by logging onto the York Electronics website (www.yorkelec.com) using the username and password created for your Dealership.
Canadian dealer online order process:
• Log in to the website.
• Click on the Bolt EV/EUV Battery Recall icon.
• Complete all required fields and submit the order.
• A copy of the order will be emailed to the email address used to log into the online order system.
• Once the order is processed by the York Electronics order desk, a confirmation email from York will be sent indicating the order was successfully received.
Note: For concerns with the online ordering process, please contact YORK ELECTRONICS OSHAWA at 1-888-650-9675 ext. 307.
Required Information for U.S. and Canada
Dealer Name: __________________
Dealer Code: _________________________
Shipping Address: ______________________________________
Contact At Dealership (include phone number and email address): _____________________
Dealerships Preferred Dealer Delivery Time/Date for Dealer Forklift Operator (Must be within 24 hours of the order time): _________________________
Hours of operation: _________________
VIN #_________________________
Model Year: _________________
Product Safety Recall
N212343881 High Voltage Battery May Melt or Burn
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Parts Retention and Return
For Markets other than US and Canada, Refer to Field Action bulletin N212343882. Parts Retention and Returns (United States Service Agents ONLY) All high voltage Li-Ion batteries are GM assets and are required to be returned. Dealers are to return the high voltage battery as soon as possible after completion of the repair. If the batteries are not returned within 30 days, the dealer will be charged back a core charge. Important: Shipment of these high voltage Li-Ion batteries is regulated by dangerous goods transportation laws. GM Dealer Parts and Accessories Policies and Procedures requires that dealers comply with all applicable dangerous goods transportation laws, including but not limited to having at least one employee be certified in the transportation of dangerous goods as required by law. Additional resources for dangerous goods transportation can be found as part of appendix G in the latest version of Service Bulletin #99-00-89-019. All dangerous goods must be shipped in accordance with all applicable federal, state, provincial, and local laws.
Drive Motor Battery Core Return Process (United States Service Agents ONLY) Important: Dealers must submit a core return request through the “Bolt EV Battery Safety Recalls” app in Global Connect. The app is available in the Global Connect App Center. It is the same app used to order batteries for the recall. DO NOT CALL CCA Logistics or XPO directly. Important: For shipping preparation instructions, refer to “Final Shipping Preparation” information following the Service Procedure at the end of this bulletin. DO NOT wait for the warranty claim to be processed before returning the removed high voltage battery. This part is GM’s material and is not claimed under the warranty labor operation. Place a copy of the repair order with the high voltage battery 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 shipping crate. DO NOT return the high voltage battery in any crate other than the crate that the service high voltage battery was delivered in. The removed unit must be returned complete in the original shipping crate. For questions about your order status, how to return exchanged material, or to verify battery receipt contact: 1-833-33 GM BSC (1-833-334-6272)
Drive Motor Battery Core Return Process (Canadian Service Agents ONLY)
Important: For shipping preparation instructions, refer to “Final Shipping Preparation” information following the Service Procedure at the end of this bulletin.
Email to arrange LTL pickup for the high voltage battery:
Send an email to: GMBatteryReturns@xpo.com.
You will be required to provide size (l x w x h) and weight. This information is available on the GM0003 tag. If your facility does not have a loading dock, please ensure XPO understands that this shipment will be loaded at ground level. (LTL carrier will need to bring required equipment).
Specify Return address:
Vancouver Serviced Dealers: Day & Ross Vancouver X-Dock
27475 58th Crescent
Langley, BC
Edmonton Serviced Dealers: Day & Ross Edmonton X-Dock
11727 – 178th Street
Edmonton, Alberta
Woodstock Serviced Dealers: Day & Ross Woodstock X-Dock
520 Beards Lane, Unit B
Woodstock, Ontario
Montreal Serviced Dealers: Day & Ross Montreal X-Dock
5000 Trans Canada Hwy
Pointe Claire, PQ
For individual batteries over 500 kg. (1102 lbs.) – included with your new battery will be four (4) Class 9 TDG placards. Please provide these to the driver and ensure placards are affixed to the vehicle before departing.
Product Safety Recall
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Refer to GM GlobalConnect for the latest GM Canada Parts Bulletin (GMP2021-213) 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.
Note: If the removed high voltage battery is 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 service high voltage battery.
Important: The high voltage battery may also be referred to drive motor battery throughout this service procedure.
Warranty Information
For Markets other than US and Canada, Refer to Field Action bulletin N212343882.
Labor Operation
Description
Labor Time
Trans. Type
Net Item
9105785*
Drive Motor Battery Replacement and Shipping Preparation (Includes Programming using ZFA – Field Action Multimodule Coordinated Sequence, Capacity Learn, EV Range Reset) (Using Forklift)
ADD: Using Engine Hoist
ADD: To Replace High Voltage Battery Coolant Cooler Outlet Hose -Only applies to MY17 Vehicles built prior to May 1, 2017
ADD: Discharge High Voltage Battery (Reduce SOC)
4.5
0.5
0.3
0.2
ZFAT
**
9106050
80 Percent SOC Adv Diag Software – waiting for HV Battery Appointment (use only if N212343883 not previously completed)
ADD: SOC Depletion to 80%
1.0
0.3
***
9105995
Working Capital Assistance Program Reimbursement – USED INVENTORY ONLY
N/A
****
Note: * To avoid having to “H” route the WCAP transaction for approval, it must be submitted prior to the repair transaction.
Important: * To avoid warranty transaction rejections, carefully read and follow the instructions below:
• The Warranty Claim Code must be accurately entered in the “Warranty Claim Code” field of the transaction.
• When more than one Warranty Claim Code is generated for a programming event, it is required to document all Warranty Claim Codes in the “Correction” field on the job card. Dealers must also enter one of the codes in the “Warranty Claim Code” field of the transaction, otherwise the transaction will reject. It is best practice to enter the FINAL code provided by SPS/SPS2.
** Submit a $520.00 USD ($624.00 CAN) administrative part allowance. Add this amount in the Administrative Allowance Net Item field when submitting the repair transaction.
** Submit a $600.00 USD ($720.00 CAN) administrative allowance for recall specific impacts to technician and service department throughput, Business Development Centers, high voltage battery handling and storage, tools and equipment, including forklifts, and miscellaneous shop supplies.
** Submit a $20.00 ($25.00 CAN) administrative allowance for return of the used high voltage battery assembly (document preparation and packaging). Add this amount in the Administrative Allowance Net Item field when submitting the repair transaction.
For Export Only – Submit an administrative allowance for return of the used high voltage battery assembly (document preparation and packaging). Add 0.2 in the labor time field when submitting the repair transaction.
** Involved vehicle owners are eligible for courtesy transportation while their vehicle is being repaired. If courtesy transportation is required, add the actual cost in the appropriate Net Item field when submitting the repair transaction. Refer to GM Warranty Administration Bulletin 18-NA-094 for Courtesy Transportation Program guidelines.
Important: *** If N212343883 (labor code 9105953) has not been previously completed, the 80% SOC Advanced Diagnostic Software is available to the customer while waiting for their high voltage battery replacement appointment. Refer to the procedure provided in N212343883. A new unique labor operation, 9106050, has been created for this programming only event. It is a non-closing labor op that will leave the safety recall open until the high voltage battery replacement procedure is completed. The ZFA – Field Action Multimodule Coordinated Sequence programming
Product Safety Recall
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must be used. Failure to use this sequential programming procedure will result in claim rejection, and may require a customer’s vehicle to return to be reprogrammed.
Warranty Claim Code Information Retrieval
If the Warranty Claim Code was not recorded on the Job Card, the code can be retrieved in the SPS system as follows: 1. Open TIS/TLC on the computer used to program the vehicle. 2. Select and start SPS/SPS2. 3. Select Settings. 4. Select the Warranty Claim Code tab.
The VIN, Warranty Claim Code and Date/Time will be listed on a roster of recent programming events. If the code is retrievable, dealers should resubmit the transaction making sure to include the code in the SPS Warranty Claim Code field.
Working Capital Assistance Program (WCAP) Reimbursement – USED INVENTORY ONLY
Note: USA & Canada Only – To avoid having to “H” route the WCAP transaction for approval, it must be submitted prior to the repair transaction.
Important: The WCAP ZSET transaction labor code, 9800076, provided in the dealer message sent on August 6, 2021, must have been submitted prior to the submittal of the ZFAT transaction labor code or the claim will reject.
**** USA & Canada Dealers Only – For vehicles eligible under the Working Capital Assistance Program, the amount should be submitted in Net Item/Miscellaneous. This amount has been calculated to a daily value for the days that the vehicle was in used dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop sale/stop delivery order July 23, 2021 to the date the VIN was placed in “open” status in IVH. (Maximum Number of days of WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH, and will be adjusted as additional releases occur.)
Vehicle
Working Capital Assistance Reimbursement Amount
USA
Canada
2017 Chevrolet Bolt EV
$6.91
$9.58
2018 Chevrolet Bolt EV
$7.79
$11.00
2019 Chevrolet Bolt EV
$8.60
$12.04
Identification Number Recording for All High Voltage Battery Replacements:
5911790
Important: (TECHNICIAN and WARRANTY ADMINISTRATOR) REQUIREMENT FOR THE SERVICE HIGH VOLTAGE BATTERY. The replacement battery identification number must be captured by the technician and recorded on the job card. The Warranty Administrator MUST enter the service high voltage battery identification number in GWM (Global Warranty Management) or in DMS (Dealer Management System). Enter the identification number of the service high voltage battery in the ‘Comments’ field per the screen above. Failure to enter this identification number will cause the claim to reject.
Tool Specifications:
Necessary tools for loading and unloading:
Forklifts are a requirement to load and unload crates from the transportation trailer.
• 3,000 lbs. (1370 kg). capacity or larger.
• 60 inch (152 cm) forks 48 inch (122 cm) are acceptable for already existing forklifts.
• Stand-up, sit-down or walkie forklifts are acceptable.
Product Safety Recall
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Page 8 of 48
Pallet Jacks are acceptable to move crates on flat surfaces including the interior of a trailer.
• 3,000 lbs. (1370 kg) capacity or larger.
• 48-60 inch (122-152 cm) forks.
• Recommended fork separation: 20 inch (51 cm).
Loading/Unloading Docks.
• Docks are preferred if available.
• Pallet Jacks are an acceptable option to load and unload in docks.
• Dock wells with grades exceeding 10% require a forklift, no pallet jacks allowed.
Necessary tools for moving crate within dealership and loading/unloading high voltage batteries in/out of crate.
Forklift (recommended).
▪ 3,000 lbs. (1370 kg) capacity; chain or lifting attachment; 48 inch (122cm) forks.
Engine Hoist (if Forklift not available).
▪ ½ ton capacity (454 kg); front leg width 36 inch (91 cm) max; lift 87 inch (221 cm) min.
▪ Process below defined for 8 inch (20 cm) top of legs.
Pallet Jack.
▪ 3,000 lbs. (1370 kg) capacity; 7 inch (18 cm) lift minimum; 48 inch (122 cm) forks.
Cribbing for REMOVED high voltage battery when using Forklift (when removing from Lift Table and placing on ground).
▪ Two (2) 4x4s length 60 inch (152 cm) (minimum).
Cribbing for REMOVED high voltage battery when using Engine Hoist (when removing from Lift Table and placing on ground).
▪ Four (4) Jack Stands –w/stable base (square) and capable of holding 1,000 lbs. (454kg).
▪ Two (2) 4x4s length 60 inch (152 cm) (minimum).
Cribbing for crate when using Engine Hoist.
▪ Two (2) 4x4s length 48 inch (122 cm) (minimum).
▪ Two (2) 4x4s length 60 inch (152 cm) (minimum).
▪ Two (2) 2x4s length 60 inch (152 cm) (minimum).
Warning: Do not use a vehicle lift to retrieve a battery from the crate or place a battery in the crate to avoid serious injury.
Personal Protective Equipment:
Loading and Unloading:
Safety glasses.
▪ General use gloves (Hy-flex, Mechanix).
▪ Substantial footwear.
Crating and Retrieving:
Safety glasses.
▪ General use gloves (Hy-flex, Mechanix).
▪ Substantial footwear.
High Voltage Battery installation/removal:
Safety glasses.
▪ Class 0 Electrical gloves with leather protectors during harness connections/disconnections.
▪ General use gloves (Hy-flex, Mechanix) for mechanical tasks.
▪ Substantial footwear.
▪ Bump caps for work underneath lifted vehicle.
High Voltage Battery Replacement Service Procedure Danger: Carefully read this bulletin before removing the vehicle’s battery and unpackaging/installing the new high voltage battery into a vehicle. This bulletin contains important legal and safety requirements that must be followed in order to safely replace the vehicle’s high voltage battery in compliance with applicable federal, state, provincial, and local laws. Failure to carefully follow these procedures may result in serious injury or death.
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• Printed instructions are also provided in the high voltage battery crate. • Do not discard or destroy the crate containing the new high voltage battery. The crate is required to return the used high voltage battery. • Read and follow the crate unloading, loading, storage, and packaging instructions in this bulletin. When shipped, the high voltage battery is regulated as dangerous goods and all service agents must follow all applicable International, Federal, State, Provincial, and/or Local laws when preparing dangerous goods shipments including but not limited to classification, packaging, marking, labeling, and shipping dangerous goods.
5903431
When lifting and moving the crate with the high voltage battery inside, be aware of the Center of Gravity (CG) as noted on the long sides of the crate. Fork mast should be centered with this mark and forks should be widened out to their maximum width and equally spaced on either side of the CG mark.
Warning: The use of a forklift is required when loading and unloading high voltage batteries into and out of delivery trucks. Other methods of loading and unloading have been deemed unsafe. Use a forklift to avoid serious injury.
Caution: Be sure to set up a temporary location for the removed battery until final shipping preparation. Do not expose the crate to rain, snow or any other environment that will cause moisture related damage.
Special Tools
• EL-48900 HEV Safety Kit.
• EL-51102 High Voltage Battery Lift Bar Tilter.
• EL-51102 – 10 Lift Lateral Bar and Shackle Set.
• EL-51102 – 20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit.
• EL-51102 – 40 Battery Lifting Strap (QTY 2).
• EL-51102 – 50 Battery Lifting Strap (QTY 4).
• EL-52016 – 1A Coolant Passage Test Adapter Kit (Included in 52016-A Kit)
• EL-52016 – 2A Coolant Pressure Tester Adapter Plug (Included in 52016-A Kit)
• GE-52200 – A Lifting Table.
For equivalent regional tools, refer to Special Tools in SI.
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.
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• 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.
Service Procedure
5905973
Important: Verify the vehicle SOC is less than 90%. This can be determined by looking at the bars on the power
level indicator. If two or more empty bars (not showing green) are displayed, the SOC is at an acceptable level. If the
power level indicator shows an SOC of greater than 90%, refer to the Vehicle Preparation Before Entering the Repair
Garage section at the beginning of this document.
Remove the Drive Motor (High Voltage) Battery
1. Disable the high voltage system. Refer to High Voltage Disabling in SI.
2. Remove the front compartment air deflector. Refer to Front Compartment Air Deflector Replacement in SI.
3. Drain the drive motor battery cooling system. The high voltage battery must be drained completely using
the Vac-N-Fill Procedure before removal from the vehicle, static draining is not sufficient. The Vac-
N-Fill Procedure must also be used when refilling the drive motor battery cooling system. If the Vac-
N-Fill Procedure is not used, the customer will return to the dealership with a low coolant condition.
Refer to Drive Motor Battery Cooling System Draining and Filling in SI.
4505400
4. Remove the high voltage battery negative cable (2) from the high voltage battery and body structure. Refer
to Battery Negative Cable Replacement in SI.
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4834281
5. Disconnect the X4 high voltage battery connector (1) from the drive motor (high voltage) battery.
6. Disconnect the X3 high voltage battery connector (2) from the drive motor (high voltage) battery by rotating the connector handle until 90 degrees.
7. Disconnect the body wiring harness connectors (3) from the drive motor (high voltage) battery.
Danger: To avoid any vehicle damage, serious personal injury, or death:
• When major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
• When performing work in the engine compartment or under the vehicle, ensure that the hood is fully open, or opened to its secondary latch. When the hood is opened to the secondary latch, the vehicle will disable the remote start features from the key fob and OnStar mobile app. Failure to open the hood or open the hood to the secondary latch while doing a repair in the engine compartment or under the vehicle can result in inadvertent vehicle starting which could result in personal injury, death, or damage to a vehicle.
Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure:
• Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.
• The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.
• The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer.
• Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.
• Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components.
Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents.
8. During drive motor battery removal, vehicle weight will be redistributed and may cause the vehicle to become unstable on the hoist. To avoid the vehicle potentially falling off, secure the vehicle to lift/hoist arms with straps.
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4507200
Warning: The GE-52200-50 lift table limiting chain is for use with GE-52200 lifting tables not equipped with a
mechanical stop. Refer to the operating instructions provided with the limiting chain. Failure to limit uncontrolled
descent of the lifting table may result in vehicle or high voltage battery damage and/or serious injury.
Note: There is a CG (Center of Gravity) mark on the drive motor battery tray to position your lift table.
Note: The high voltage battery mass is approximately 1000 lbs. (450 kg).
9. Position a GE-52200 Lifting Table and raise the lifting table into position.
4834282
Note: Verify ALL connectors are removed from the drive motor battery.
Note: Confirm the locking MSD cap/cover required in some regions will pass through the vehicle floor panel. If
not, the MSD cap/cover should be removed during high voltage battery lowering from vehicle then reinstalled once
the battery is out.
Note: Ensure all fasteners are removed before lowering the support table fixture with the drive motor battery.
10. Remove the drive motor battery mounting fasteners (1).
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Danger: When removing the high voltage battery, only use the recommended lift table with straps capable of holding
2205 lbs. (1000kg). Failure to use the appropriate lift table and straps could cause the battery to fall and
may result in serious injury or death.
11. Slowly lower the lifting table (1) with the drive motor battery (2).
12. Secure the high voltage battery to the lifting table with straps.
Removed Battery Cribbing Setup with Forklift
1. Set-up two (2) 4x4s 27 inches apart (69 cm) (inside measurement) to allow battery frame to sit on 4x4s.
Caution: DO NOT place battery directly on ground or directly on jack stands (without 4x4s).
4587656
2. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2)
and bolts (1). The longer bolts should be used on the “heavy” side of the battery.
4587657
3. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2)
and bolts (1). The longer bolts should be used on the “heavy” side of the battery.
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4587658
Assemble Lifting Kit
• EL-51102 High Voltage Battery Lift Bar Tilter (1).
• EL-51102–10 Hanging Bars and Shackles (2).
• EL-51102–40/50 Battery Lifting Strap (3) and (4).
4. Attach Lifting Kit to forklift (with appropriate chain/attachment).
5. Position the EL-51102 High Voltage Battery Lift Bar Tilter and EL-51102–10 Hanging Bars and Shackles (2)
over the high voltage battery.
6. Attach lift kit straps to eyebolts on REMOVED high voltage battery on Lift Table.
• Ensure Lifting Straps (4) attach the heavy end of the high voltage battery.
• Adjust Tilter to bias the vertical bar about 8 inches from end with the handle.
Note: Make sure the drive motor battery is balanced when hung from the lifting straps before moving with a
forklift (with appropriate chain/attachment) to the Lifting Table.
Note: As part of the battery removal process, all coolant should be drained from the high voltage battery. The
high voltage battery must be drained completely using the Vac-N-Fill Procedure before removal from the
vehicle. Static draining is not sufficient. The Vac-N-Fill Procedure must also be used when refilling the
drive motor battery cooling system. If the Vac-N-Fill Procedure is not used, the customer will return to
the dealership with a low coolant condition. Refer to Drive Motor Battery Cooling System Draining and
Filling in SI.
7. Use forklift to lift REMOVED high voltage battery from Lifting Table.
8. Slowly lower REMOVED high voltage battery onto cribbing.
9. Confirm battery is secure on cribbing.
• Take almost all tension off the lifting straps and gently jostle high voltage battery to ensure stability.
10. Detach lifting kit straps from eyebolts.
11. Disconnect all six (pin/ bolt) assemblies from the high voltage battery and remove bolts/pins and lifting
harness off of the high voltage battery.
Unloading Service High Voltage Battery from crate using FORKLIFT (If using Engine Hoist refer to Engine Hoist
instructions.)
These crates are intended/rated for reuse and should be handled with care. Do not expose the crate to rain,
snow or any other environment that will cause moisture related damage.
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1. Inspect crate, all components for damage. If crate and components are found to be free from damage proceed
to step 2. If crate and/or components are damaged, see end of closure instruction for contact information for
replacement crate and/or components.
5903436
2. Remove (12) 1/2 inch hex head X 5/16 inch dia. x 4 inch lag screws. Place lag screws and washers in a separate
container to be reused to close the crate once the removed high voltage battery is loaded.
5903437
3. Using lid handles, lift off the lid with (2) people.
5903438
4. Carefully set lid aside so as to not damage the foam on the inside of the crate lid.
5903439
5. Remove supplied items; 1 x gusseted poly bag, (1) 18 inch x 16 inch (46 x 41 cm) perforated absorbent pad, and
2 x absorbent pads, set these aside to be used for the return of the removed high voltage battery at a later step.
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5903440
6. Using a T-20 or T-25 Torx bit (material shortages drove the need for either size) remove the 16 screws holding
the 2 horizontal crossbars in place (save screws to re-secure in a future step).
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5903442
7. Release (2) cinch straps and position along the outside of crate on both sides. Tuck straps under crate to avoid
tripping hazard.
5903443
IMPORTANT: Screws will NOT be used when the removed high voltage battery is returned in the crate and
can be discarded. DO NOT REUSE LAG SCREWS.
8. Remove all 4 lag screws securing the SERVICE high voltage battery in the crate and dispose of screws
appropriately (2 on each side of the battery). Screws will NOT be used when the removed high voltage battery
is returned in the crate-DO NOT REUSE LAG SCREWS.
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9. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” side of the high voltage battery.
4587657
10. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” side of the high voltage battery.
11. Position the EL-51102 High Voltage Battery Lift Bar Tilter and EL-51102–10 Hanging Bars and Shackles (2) over
the high voltage battery.
12. Attach lift kit straps to eyebolts on service high voltage battery in crate.
• Ensure Lifting Straps (4) attach the heavy end of the high voltage battery.
• Adjust Tilter to bias the vertical bar about 8 inch (20 cm) from end with the handle.
Note: Make sure the drive motor battery is balanced when hung from the lifting straps before moving with a forklift
(forks together with appropriate chain/attachment) to the Lifting Table.
5903444
13. Carefully begin to raise the service high voltage battery out of the crate. Avoid contacting the foam lining of the
crate with the high voltage battery. If foam is torn and cannot be repaired or reattached, it must be replaced.
14. Move the crate away from the suspended high voltage battery. Move the lift table under the high voltage battery.
15. Lower SERVICE high voltage battery onto Lift Table and confirm stability.
16. Secure the SERVICE high voltage battery to the lifting table with straps.
17. Detach lifting kit straps from eyebolts on SERVICE high voltage battery on Lifting Table.
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18. Remove lifting kit eyebolts from SERVICE high voltage battery.
19. Remove coolant plugs from SERVICE high voltage battery -DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
20. Remove MSD cover from the SERVICE high voltage battery -DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
21. Remove High and Low Voltage Connector Covers from the SERVICE high voltage battery -DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
High Voltage Battery Installation Procedure
4507203
22. Avoid making contact between the rear of the drive motor battery and the rear suspension bushing bolts.
4587655
Warning: The GE-52200-50 lift table limiting chain is for use with GE-52200 lifting tables not equipped with a mechanical stop. Refer to the operating instructions provided with the limiting chain. Failure to limit uncontrolled descent of the lifting table may result in damage and/or serious injury.
23. With the drive motor battery (2) on the GE-52200 Lifting Table (1), slowly raise the lifting table.
24. Release the straps.
25. Continue to raise the battery into position for installation.
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Caution: Refer to Fastener Caution in SI.
26. Snugly tighten the outside mounting fasteners (1).
27. Lower the lifting table.
28. Tighten the fasteners (1) to 56 Nm (41 lb. ft).
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29. Connect the body wiring harness connectors (3) to the drive motor (high voltage) battery.
30. Connect the X3 high voltage connector (2) to the drive motor (high voltage) battery.
31. Connect the X4 high voltage connector (1) to the drive motor (high voltage) battery.
4505400
32. Install the battery negative cable (2) to the high voltage battery and body structure. Refer to Battery Negative Cable Replacement in SI.
33. Untie the straps that are installed to avoid the vehicle potentially falling off from the lift/hoist.
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34. Fill the drive motor battery cooling system. The high voltage battery must be drained completely using the Vac-N-Fill Procedure before removal from the vehicle. Static draining is not sufficient. The Vac-N-Fill Procedure must also be used when refilling the drive motor battery cooling system. If the Vac-N-Fill Procedure is not used, the customer will return to the dealership with a low coolant condition. Refer to Drive Motor Battery Cooling System Draining and Filling in SI.
34.1. Disconnect the 12v battery after completing the coolant filling procedure.
35. Check the cooling system for leaks. Refer to Hybrid Cooling System Leak Test in SI.
36. Install the front compartment air deflector. Refer to Front Compartment Air Deflector Replacement in SI.
37. Enable the high voltage system. Refer to High Voltage Enabling in SI.
38. Reprogram multiple modules using ZFA – Field Action Multimodule Coordinated Sequence through SPS/Techline Connect. Refer to Programming section below.
Important: Be sure to complete the Hybrid/EV Battery Pack Capacity Learn and EV Range Reset following the steps in the Programming section below.
Programming
Note: Carefully read and follow the instructions below.
• Ensure the programming tool is equipped with the latest software and is securely connected to the data link connector. If there is an interruption during programming, programming failure or control module damage may occur.
• Stable battery voltage is critical during programming. Any fluctuation, spiking, over voltage or loss of voltage will interrupt programming. Install a GM Authorized Programming Support Tool to maintain system voltage. Refer to www.gmdesolutions.com for further information. If not available, connect a fully charged 12 V jumper or booster pack disconnected from the AC voltage supply. DO NOT connect a battery charger.
• Follow the on-screen prompts regarding ignition power mode but ensure that anything that drains excessive power (exterior lights, HVAC blower motor, etc.) is off.
• Clear DTCs after programming is complete. Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to NO.
Important: The service technician always needs to verify that the VIN displayed in the TLC left side drop down menu and the top center window match the VIN plate of the vehicle to be programmed prior to using Service Programming System 2 (SPS2) for programming or reprogramming a module.
• For the TLC application, service technicians need to always ensure that the power mode (ignition) is “ON” before reading the VIN from the vehicle’s VIN master module and that they do not select a VIN that is already in the TLC application memory from a previous vehicle.
• If the VIN that shows up in the TLC top center window after correctly reading the VIN from the vehicle does not match the VIN plate of the vehicle, manually type in the VIN characters from the vehicle VIN plate into the TLC top center window and use these for programming or reprogramming the subject module with the correct vehicle VIN and software and/or calibrations.
Caution: Be sure the VIN selected in the drop-down menu (1) is the same as the vehicle connected (2) before beginning programming.
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5743643
Important: If the vehicle VIN DOES NOT match, the message below will be shown.
5877000
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5431207
Important: Techline Connect and TIS2WEB screens shown above.
Important: If the same calibration/software warning is noted on the TLC or SPS Summary screen, select OK and
follow screen instructions. After a successful programming event, the WCC is located in the Service Programming
System dialogue box of the SPS Summary screen. No further action is required. Refer to the Warranty section of the
bulletin.
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5431209
Note: The screenshots above are an example of module programming and may not be indicative of the specific
module that is being programmed. Module selection and VIN information have been blacked out.
Important: To avoid warranty transaction rejections, you MUST record the warranty claim code provided on the
Warranty Claim Code (WCC) screen shown above on the job card. Refer to callout 1 above for the location of the
WCC on the screen. Labor Op. 9105785 – ZFA – Field Action Multimodule Coordinated Sequence MUST be used
or your claim will reject.
1. Reprogram the sequential multiple modules through SPS/Techline Connect (SPS and Techline Connect screens
shown) by selecting “ZFA – Field Action Multimodule Coordinated Sequence” on the select controller screen
and select “Programming” for the Select Function/Sequence. Select “Next” and follow all on screen instructions.
In SPS, scroll down to view all instructions prior to programming.
5924567
Note: Programming MUST be completed using the ZFA – Field Action Multimodule Coordinated Sequence,
otherwise the warranty claim will be rejected. When using the ZFA – Field Action Multimodule Coordinated
Sequence, the first module in the sequence is the K114B HPCM2 which is programmed with Ignition OFF and the
brake pedal depressed to keep communications awake. The second module in the sequence is the K16 BECM, which
is programmed with Ignition ON/Propulsion OFF. The third module is the K9 BCM is also programmed with Ignition
ON/Propulsion OFF.
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Note: Failure to make the transition to Ignition ON/Propulsion OFF may result in having to restart the sequential programming. Sequential programming may SKIP some modules if they already have the latest available calibration.
2. Remain in the vehicle with the brake pedal depressed during the programming of the K114B HPCM2. When the green check mark indicates the K114B HPCM2 has been re-programmed, as shown in the image, release the brake pedal and transition to Ignition ON/Propulsion OFF.
Hybrid/EV Battery Pack Capacity Learn and EV Range Reset
Perform the Hybrid/EV battery pack capacity learn using the steps below.
1. The Hybrid/EV Battery Pack Capacity Learn procedure can be activated with a scan tool using the following steps:
1.1. Vehicle on.
1.2. With a scan tool, select Hybrid Powertrain Control Module 2 and observe and record the Hybrid/EV Battery Pack Capacity scan tool parameter.
5892485
1.3. Select Hybrid Powertrain Control Module 2 Configuration/Reset Functions. Select the Learn Functions — Hybrid/EV Battery Pack Capacity Learn and command a Learn.
5882921
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5882922
1.4. Using GDS2, reset the EV Range by selecting “Reset Functions” then “EV Range Reset”.
Return Vehicle to 100% Charging
For 2017 and 2018 model year vehicles, disable Hill Top Reserve:
1. To change Hill Top Reserve in the center infotainment display, touch Energy, and then touch Energy Settings. Use the arrows to scroll through the list.
2. Confirm Hill Top Reserve is set to “off”.
For 2019 model year vehicles:
1. Set Target Charge Level to 100%. To change the Target Charge Level in the center infotainment display, touch Energy and then touch Charging.
1.1. Touch the Target Charge Level tab on the Charging screen.
1.2. Touch “+” (plus) to increase the charge level to 100%.
2. Remove the masking tape from the charge receptacle door. If the customer is not waiting, charge the vehicle to full capacity. The charge is complete when the green light on the top of the dash pad is solid green. DC Fast Charging may be used.
5882923
3. Record SPS Warranty Claim Code AND the new replacement high voltage battery identification number on job card for warranty transaction submission. The high voltage battery identification number is located on the left side of the high voltage battery. The identification number contains the letters “RES” in the middle of the number.
Removed Battery Return Preparation Danger: The high voltage battery must be protected when outside of the vehicle. The battery should be placed in the shipping crate from the service battery as soon as possible to avoid serious injury or death. After the high voltage battery has been removed from the vehicle and before placement into the shipping crate, prepare the high voltage battery for return by performing the following steps:
1. Install the coolant plugs. There are 2 of them in the coolant lines. The coolant plugs were removed from the service high voltage battery assembly and must be installed in the removed high voltage battery. Additional coolant plugs (GM P/N 22770854) can be ordered if they are needed.
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Note: The Drive Motor Battery High Voltage Manual Disconnect Lever is also known as the S15 Manual
Service Disconnect (MSD).
2. Install the Manual Service Disconnect (MSD) Cover. The MSD cover was removed from the new service battery
assembly and must be installed in the returned battery. The MSD lever must remain with the vehicle and not be
returned with the removed high voltage battery.
3. Install the High and Low Voltage Connector Covers. The covers can be removed from the service high voltage
battery and installed on the removed high voltage battery.
Crating of REMOVED High Voltage Battery using FORKLIFT (If using Engine Hoist refer to Engine Hoist
instructions).
Connect Lifting Kit to REMOVED High Voltage Battery
Follow technical specification to connect the GM approved Lifting Kit to the high voltage battery.
4587656
1. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” end of the high voltage battery.
4587657
2. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” end of the high voltage battery.
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4587658
3. Attach lift kit straps to eyebolts on REMOVED high voltage battery.
• Ensure Lifting Straps (4) attach the heavy end of the high voltage battery.
• Adjust Tilter to bias the vertical bar about 8 inches from end with the handle.
REMOVED High Voltage Battery Return Shipping Preparation using FORKLIFT (If using Engine Hoist refer to
Engine Hoist instructions).
5903431
When lifting and moving the crate with the removed high voltage battery inside, be aware of the Center of Gravity (CG)
as noted on the long sides of the crate. Fork mast should be centered with this mark and forks should be widened out to
their maximum width and equally spaced on either side of the CG mark.
Important: The high voltage battery is regulated under dangerous goods transportation laws. As the shipper of
record, dealers are responsible for compliance with all applicable international, federal, state, provincial, or local
dangerous goods transportation laws. This includes, but is not limited to proper labeling, marking, completion of
shipping papers, and packaging. Failure to comply with federal dangerous goods transportation laws may result in a
violation of the U.S. Hazardous Materials Transportation Act, as amended, and its implementing regulations issued
by the U.S. Department of Transportation at Title 49, Volumes 2-3, of the Code of Federal Regulations and could
subject you to fines of up to $84,425 for each violation, or criminal penalties. Similarly, in Canada, failure to comply
with the Transportation of Dangerous Goods Act and Regulations may subject you to fines.
These crates are intended/rated for reuse and must be handled with care. Do not expose the crate to rain, snow or any
other environment that will cause moisture related damage.
Replacement packing material for shipping:
5903430
• US dealers-If required, obtain replacement packaging materials through the SNT app in Global Connect (Same
app used to order and return high voltage batteries).
• Canadian dealers- If required, obtain replacement packaging materials through YORK ELECTRONICS
OSHAWA at 1-888-650-9675 ext. 307.
• For Markets other than US and Canada, Refer to Field Action bulletin N212343882.
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5903442
1. Position the cinch straps over the edge of the crate and ensure buckles are outside the crate. Tuck any excess
length of straps under the crate to avoid a tripping hazard.
5903445
2. Return previously removed poly bag to crate. Open the gusseted poly bag and lay the seam of the bag along
the center line of the crate floor.
a. The 81 inch (206 cm) length should be run along the long side of the crate.
b. The 58 inch (147 cm) length should run along the short side of the crate.
c. Carefully tuck polybag into the bottom of the crate. Ensure that polybag is pushed down into corners
and touches inside of crate floor.
Important: Use extreme caution to ensure poly bag is NOT torn during this process. A torn poly bag will need to
be replaced. See contact information at the end of the closure instructions for questions, or ordering replacement
crate components.
5903446
3. Grab one (1) of previously removed absorbent pads and lay in bottom of crate on top of poly bag.
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5903447
4. Align one edge with vertical wood supports. Fold over 12 inches (30 cm) of absorbent liner along the other side
of the crate, all vertical supports should now be visible. This will help to ensure battery is properly seated in the
crate.
4587658
5. Follow technical specifications to connect the GM approved lift kit to the high voltage battery.
5903460
5903448
6. Ensure the heavy end of the high voltage battery is aligned to the end of the crate stenciled “heavy end”. Ensure
the crate and the forklift are squared up to one another.
5903449
7. Carefully lower the high voltage battery into the crate so as not to tear the bag or absorbent liner. Ensure the
high voltage battery is leveled in the crate.
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CAUTION: Ensure none of the high voltage battery “feet” are resting on any of the vertical supports. The high voltage
battery feet need to be in between the vertical supports to avoid high voltage battery damage.
8. Confirm the following measurements to ensure high voltage battery is seated properly before proceeding.
• At least 2 inches (5 cm) from top surface of #2 and #4 bars to top edge of vertical wood support (confirm at
all 4 bars).
• At least 16 inches (41 cm) from top surface of flange to top edge of crate at heavy end of high voltage
battery.
• At least 13 ½ inches (34 cm) from top surface of flange to top edge of crate at light end of high voltage
battery.
Danger: Measurements need to be taken at all 6 locations to ensure fully seated. Failure to carefully follow these
procedures may result in serious injury or death.
9. If these measurements at not met at ALL 6 locations the battery is not properly seated and should be lifted,
repositioned using tag lines and lowered again.
Danger: Measurements need to be retaken at all 6 locations to ensure fully seated. Failure to carefully follow
these procedures may result in serious injury or death
Warning: If battery is not fully seated and meet the above measurements, the high voltage battery could shift when
removing Lifting Strap Pin Bolts and hands/fingers could be crushed by weight of high voltage battery.
10. Once above measurements are taken and it is confirmed the high voltage battery is fully seated, disconnect lifting
straps.
5903450
11. Disconnect all six (eyenut/bolt) assemblies from the high voltage battery. Remove eyenuts/bolts and lifting
harness off of the high voltage battery and out of full cycle crate.
5903454
12. Open second absorbent pad, place on top of the high voltage battery as shown on the picture above, tuck the
absorbent pad around the high voltage battery.
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5903455
13. Fold the gusseted poly bag as follows:
a. Fold excess poly bag material on one short side of crate over end of high voltage battery.
b. Repeat for opposite short side of poly bag.
5903456
14. Fold excess poly bag material along one of the long sides of crate across the side of high voltage battery. Repeat
for the opposite long side of poly bag.
5903457
15. Loosely secure cinch straps and take the 18 inch x 16 inch (46 x 41 cm) perforated absorbent pad, tear at
perforation and place 1 pad under each of the 2 buckles to prevent any chaffing, or tears on the poly bag. Pull 2
cinch straps tight.
5903458
Important: Be sure to install the 2 horizontal crossbars on each side of the crate to ensure Dangerous Goods
Compliance.
16. Using the previously removed 16 x T20 or T25 Torx head screws, reattach (2) horizontal crossbars on each side
of the crate. Do not over tighten. Screws should be flush with top surface of the crossbar.
Important: DO NOT reinstall original lag screws securing the battery. Use extreme caution to ensure the poly bag
is not pierced or torn to ensure compliance with dangerous goods transportation laws.
Important: Place a copy of the repair order with the high voltage battery to be returned. Failure to return a copy of
the repair order with the shipment may result in a debit.
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5903460
17. Return the lid to top of crate lifting by the handles on the top of the lid, ensure the HEAVY END on lid aligns
with heavy end on the side of the crate. Carefully attach the lid using the (12) 1/2 inch hex head x 5/16 inch
dia. x 4 inch lag screws that were loosened when the new battery was removed from the crate. Do not apply
more than the maximum torque of 84-117 in-lbs. (7 – 9.75 ft-lbs.) (.97 – 1.24 – kg-m).
5903461
5903462
18. Reverse the (2), Class 9 labels to read Damaged / Defective (one on each side of the crate).
c. Open the three (3) release clips and reverse the labels to show UN3480 – DAMAGE / DEFECTIVE side.
d. Close the three (3) clips to secure the Class 9 label in place.
5903463
19. Do not stack loaded crates more than 3 high. Maximum stacking weight 6,579 lbs. (2984kg). Ensure gross
package weight does not exceed the UN specification mark on the package of 1645 lbs. (746 KG).
Caution: Be sure to set up temporary location for the removed battery until final shipping preparation. Do not
expose the crate to rain, snow or any other environment that will cause moisture related damage.
Ensure that all legal requirements for shipment of this material have been met, including those applicable to you as
the shipper of dangerous goods/hazardous materials.
Contact and Website Information
Important: For assistance with any dangerous goods relating to packaging or shipping information,
please contact the Dangerous Goods and Container Question Hotline (English, Spanish and French) at:
• 1 (844) 931-4966
• Hours of Operation – Monday through Friday 8 a.m. – 5 p.m. US Central Standard Time.
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Please refer to your region’s GM Bulletin for the latest updates associated with this recall campaign. GM bulletins:
• N212343882, (export only)
• N212345942. (export only)
Important: The high voltage battery is regulated under dangerous goods transportation laws. As the shipper of
record, dealers are responsible for compliance with all applicable international, federal, state, provincial, or local
dangerous goods transportation laws. This includes, but is not limited to proper labeling, marking, completion of
shipping papers, and packaging. Failure to comply with federal dangerous goods transportation laws may result in a
violation of the U.S. Hazardous Materials Transportation Act, as amended, and its implementing regulations issued
by the U.S. Department of Transportation at Title 49, Volumes 2-3, of the Code of Federal Regulations and could
subject you to fines of up to $84,425 for each violation, or criminal penalties. Similarly, in Canada, failure to comply
with the Transportation of Dangerous Goods Act and Regulations may subject you to fines.
Using Engine Hoist and Pallet Jack Method for Uncrating/Crating
Removal of Removed High Voltage Battery from Lifting Table using Engine Hoist
Connect Lifting Kit to Removed High Voltage Battery
Follow technical specification to connect the GM approved Lifting Kit to the high voltage battery.
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1. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” end of the high voltage battery.
4587657
2. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” end of the high voltage battery.
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Assemble Lifting Kit
• EL-51102 High Voltage Battery Lift Bar Tilter (1)
• EL-51102–10 Hanging Bars and Shackles (2)
• EL-51102–40/50 Battery Lifting Strap (3) and (4)
3. Attach Lifting Kit to engine hoist with appropriate attachment.
4. Move engine hoist to location where REMOVED high voltage battery will be staged (ensure sufficient spacing
to remove Lifting Table and position Shipping crate).
Important: Make sure there is enough room between the crate, Lifting Table and engine hoist as the engine hoist
with the battery attached CANNOT be moved.
5. Move Lift Table with removed high voltage battery under engine hoist.
6. Attach lift kit straps to eyebolts on REMOVED high voltage battery on Lift Table.
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• Ensure Lifting Straps (4) attach the heavy end of the high voltage battery.
• Adjust Tilter to bias the vertical bar about 8 inches (20 cm) from end with the handle.
Note: Make sure the drive motor battery is balanced when hung from the lifting straps before lowering to the Lifting
Table.
Note: As part of the high voltage battery removal process, all coolant should be drained from the high voltage
battery. The high voltage battery must be drained completely using the Vac-N-Fill Procedure before removal
from the vehicle. Static draining is not sufficient. The Vac-N-Fill Procedure must also be used when refilling
the drive motor battery cooling system. If the Vac-N-Fill Procedure is not used, the customer will return to
the dealership with a low coolant condition. Refer to Drive Motor Battery Cooling System Draining and Filling in
SI.
7. Use Engine Hoist to lift removed high voltage battery from Lifting Table and then move Lifting Table out from
under high voltage battery/hoist.
Danger: To avoid serious injury or death, follow the instructions below:
• DO NOT MOVE THE ENGINE HOIST WITH THE HIGH VOLTAGE BATTERY ATTACHED.
• DO NOT go under the engine hoist with the high voltage battery attached.
• DO NOT maneuver the high voltage battery with the Lifting Kit straps.
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5903432
5903803
8. Set-up cribbing under Hoist & high voltage battery to place REMOVED high voltage battery on from the Lifting
Table.
• Set-up jack stands and two (2) 4x4s 27 inches (69 cm) apart (inside measurement) to allow battery frame
to sit on 4x4s. Jack stands should be placed at outer edge of high voltage battery at bar location (1) and (5)
as shown above.
Caution: DO NOT place high voltage battery directly on ground or directly on jack stands without 4x4s to avoid high
voltage battery damage.
9. Slowly lower REMOVED high voltage battery onto cribbing.
10. Confirm high voltage battery is secure on cribbing.
• Take almost all tension off the lifting straps and gently jostle high voltage battery to ensure stability.
11. Detach lifting kit straps from eyebolts (leave lifting kit attached to Hoist) and move hoist.
Unloading SERVICE High Voltage Battery from Crate using Engine Hoist
5903435
1. Inspect crate, all components for damage. If crate and components are found to be free from damage proceed
to Step 2. If crate and/or components are damaged, see end of closure instruction for contact information.
5903436
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2. Remove (12) 1/2 inch hex head X 5/16 inch dia. x 4 inch lag screws. Place lag screws and washers in a separate
container to be reused to close the crate once the removed high voltage battery is loaded.
5903437
3. Using lid handles, lift off the lid with (2) people.
5903438
4. Carefully set lid aside so as to not damage the foam on the inside of the crate lid.
5903439
5. Remove supplied items; 1 x gusseted poly bag, (1) 18 inch x 16 inch (46 x 41 cm) perforated absorbent pad, and
2 x absorbent pads. Set these aside to be used for the return of the removed high voltage battery at a later step.
5903440
6. Using a T-20 or T-25 Torx bit (material shortages drove the need for either size) remove the 16 screws holding
the 2 horizontal crossbars in place (save screws to re-secure in a future step).
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5903441
5903442
7. Release (2) cinch straps and position along the outside of crate on both sides. Tuck straps under crate to avoid tripping hazard.
5903443
Important: Lag screws will NOT be used when the removed high voltage battery is returned in the crate and can be discarded. DO NOT REUSE LAG SCREWS.
8. Remove all 4 lag screws securing the high voltage battery in the crate and dispose of screws appropriately (2 on each side of the high voltage battery). Screws will NOT be used when the removed high voltage battery is returned in the crate-DO NOT REUSE LAG SCREWS.
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9. Remove lifting kit eyebolts from REMOVED high voltage battery and install on SERVICE high voltage battery (connect to the #1, #3, and #5 bars on the high voltage battery).
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5903444
10. Measure clearance needed for engine hoist legs to fit under the crate (instruction below are for 8 inch clearance,
adjust appropriately for hoist leg clearance).
11. Crib the crate & pallet jack.
11.1. Use pallet jack to raise crate ~4-5 inches (10-13 cm) and place 4×4 ~60 inch (152 cm) under each
runner at ends of crate and lower crate so crate runners rest on 4x4s.
11.2. Put two 4x4s (~36 inch length) (91 cm) on Pallet Jack forks.
11.3. Raise crate using Pallet Jack (w/4x4s on it) to raise crate additional 2-3 inches (5-8 cm) and place 2×4
on existing 4×4 under each runner at ends of crate and lower crate so runners rest on the 2x4s.
12. Verify engine hoist clearance is met.
13. Position engine hoist over crate with lifting kit attached.
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14. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” side of the high voltage battery.
4587657
15. Using the EL-51102–20 High Voltage Battery Lift Bar Tilter Eye-Nut Kit install the 3 eye-nut (3), washers (2) and
bolts (1). The longer bolts should be used on the “heavy” side of the high voltage battery.
16. Position the EL-51102 High Voltage Battery Lift Bar Tilter and EL-51102–10 Hanging Bars and Shackles (2) over
the high voltage battery.
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17. Attach lift kit straps to eyebolts on service high voltage battery in crate.
18. Ensure Lifting Straps (4) attach the heavy end of the high voltage battery.
19. Adjust Tilter to bias the vertical bar about 8 inches (20 cm) from end with the handle.
5903444
20. Carefully begin to raise the service high voltage battery out of the crate. Avoid contacting the foam lining of the crate with the battery. If foam is torn and cannot be repaired or reattached, it must be replaced.
Warning: To avoid serious injury, DO NOT MOVE THE ENGINE HOIST WITH THE HIGH VOLTAGE BATTERY ATTACHED.
21. Using a pallet jack, move the empty crate away from engine hoist (move crate cribbing also being sure to maintain stability).
22. Position lift table under SERVICE high voltage battery.
23. Lower SERVICE high voltage battery onto Lift Table and confirm stability.
24. Secure the high voltage battery to the lifting table with straps.
25. Detach lifting kit straps from eyebolts on SERVICE high voltage battery on table.
26. Remove lifting kit eyebolts from SERVICE high voltage battery.
27. Remove coolant plugs from SERVICE high voltage battery-DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
28. Remove MSD cover from the SERVICE high voltage battery -DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
29. Remove High and Low Voltage Connector Covers from the SERVICE high voltage battery-DO NOT DISCARD. Will be used with removed high voltage battery for shipping.
30. Install SERVICE high voltage battery in vehicle from table. Refer to Drive Motor Battery Replacement and Shipping Preparation.
REMOVED High Voltage Battery Return Shipping Preparation using Engine Hoist After the high voltage battery has been removed from the vehicle and before placement into the shipping crate, prepare the high voltage battery for return by performing the following steps:
1. Install the coolant plugs. There are 2 of them in the coolant lines. The coolant plugs can be removed from the new SERVICE high voltage battery assembly and installed in the returned high voltage battery. Additional coolant plugs (GM P/N 22770854) can be ordered if they are needed. Note: The Drive Motor Battery High Voltage Manual Disconnect Lever is also known as the S15 Manual Service Disconnect (MSD).
2. Install the Manual Service Disconnect (MSD) Cover. The MSD cover can be removed from the new SERVICE high voltage battery assembly and installed in the removed high voltage battery. The MSD lever should remain with the vehicle and not be returned with the removed high voltage battery assembly.
3. Install the High and Low Voltage Connector Covers. The covers can be removed from the SERVICE high voltage battery and installed on the removed battery. Final Shipping Preparation Replacement packing material for shipping:
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5903430
• US dealers-If required, obtain replacement packaging materials through the SNT app in Global Connect (Same app used to order and return batteries).
• Canadian dealers- If required, obtain replacement packaging materials through YORK ELECTRONICS OSHAWA at 1-888-650-9675 ext. 307.
• For Markets other than US and Canada, Refer to Field Action bulletin N212343882. 5903431 When lifting and moving the crate with the high voltage battery inside, be aware of the Center of Gravity (CG) as noted on the long sides of the crate. Fork mast should be centered with this mark and forks should be widened out to their maximum width and equally spaced on either side of the CG mark.
Packing/Closure Instructions for Full Cycle Crate for DDR Battery Returns Using Engine Hoist
Loose crate components to support return of DDR battery:
1 – 81 inch (206cm) x 58 inch (148cm) x 96 inch (244cm) gusseted poly bag
2 – 57 inch (145cm) x 80 inch (203cm) absorbent poly bags
1 – 18 inch (46cm) x 16 inch (41cm) perforated absorbent pad
IMPORTANT: The high voltage battery is regulated under dangerous goods transportation laws. As the shipper of record, dealers are responsible for compliance with all applicable international, federal, state, provincial, or local dangerous goods transportation laws. This includes, but is not limited to proper labeling, marking, completion of shipping papers, and packaging. Failure to comply with federal dangerous goods transportation laws may result in a violation of the U.S. Hazardous Materials Transportation Act, as amended, and its implementing regulations issued by the U.S. DOT at Title 49, Volumes 2-3, of the CFR and could subject you to fines of up to $84,425 for each violation, except the maximum fine is $196,992 if the violation results in death, serious illness, or severe injury to any person or substantial destruction of property. Failure to follow these closure instructions may result in a violation of the U.S. Hazardous Materials Transportation Act and could subject you to fines as previously referenced.
The packaging referenced has passed the standards of the DOT’S TITLE 49 CFR; Performance Oriented Packaging Standards, Section 178. This package is also certified under ADR, IMDG, ICAO/IATA Regulations and the UN Recommendations on the Transport of Dangerous Goods. It is the responsibility of the end user to determine authorization for use under these regulations. The use of other packaging methods or components other than those documented in this report may render this certification invalid. These crates are intended/rated for reuse and must be handled with care. Do not expose the crate to rain, snow or any other environment that will cause moisture related damage.
After the SERVICE high voltage battery has been removed, inspect crate, and all components for damage. If crate is found to be free from damage proceed to next step. If crate is damaged, contact Labelmaster for guidance and or replacement parts. Labelmaster contact information is at the bottom of this instruction sheet.
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5903442
1. Position the cinch straps over the edge of the crate and ensure buckles are outside the crate. Tuck any excess
length of straps under the crate to avoid a tripping hazard.
5903445
2. Return previously removed poly bag to crate. Open the gusseted poly bag and lay the seam of the bag along
the center line of the crate floor.
2.1. The 81 inch (206 cm) length should be run along the long side of the crate.
2.2. The 58 inch (147 cm) length should run along the short side of the crate.
2.3. Carefully tuck poly bag into the bottom of the crate. Ensure that poly bag is pushed down into corners
and touches inside of crate floor.
Important: Use extreme caution to ensure poly bag is NOT torn during this process. A torn poly bag will need to
be replaced. See contact information at the end of the closure instructions for questions, or ordering replacement
crate components.
5903446
3. Grab one (1) of previously removed absorbent pads and lay in bottom of crate on top of poly bag.
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5903447
4. Align one edge with vertical wood supports. Fold over 12 inches (30 cm) of absorbent liner along the other side
of the crate, all vertical supports should now be visible. This will help to ensure high voltage battery is properly
seated in the crate.
5. Move engine hoist so it is positioned over removed high voltage battery.
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6. Follow technical specifications to connect the GM approved lift kit to the high voltage battery.
7. Lift removed high voltage battery from jack stand cribbing then move cribbing out of the way.
8. Position and crib the crate & pallet jack under removed high voltage battery hanging on hoist.
8.1. Use pallet jack to raise crate ~4-5 inches (10-13 cm) and place 4×4 ~ 60 inches (152 cm) under each
runner at ends of crate and lower crate so crate runners rest on 4x4s.
8.2. Put two 4x4s (~36 inch length) (91 cm) on pallet jack forks.
8.3. Raise crate using pallet jack (w/4x4s on it) to raise crate additional 2-3 inches (5-8 cm) and place 2×4 on
existing 4×4 under each runner at ends of crate and lower crate so runners rest on the 2x4s.
9. Confirm crate, with poly bag in place, is aligned appropriately under the high voltage battery on the engine hoist.
10. Ensure the heavy end of the high voltage battery is aligned to the end of the crate stenciled “heavy end”. Ensure
the crate and the fork truck /or engine hoist are squared up to one another.
5903448
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5903449
11. Carefully lower the high voltage battery into the crate so as not to tear the poly bag or absorbent liner. Ensure
the high voltage battery is leveled in the crate.
12. Confirm the following measurements to ensure high voltage battery is seated properly before proceeding.
• At least 2 inches (5 cm) from top surface of #2 and #4 bars to top edge of vertical wood support (confirm at
all 4 bars).
• At least 16 inches (41 cm) from top surface of flange to top edge of crate at heavy end of high voltage battery.
• At least 13 ½ inches (34 cm) from top surface of flange to top edge of crate at light end of high voltage
battery.
Danger: Measurements need to be taken at all 6 locations to ensure fully seated. Failure to carefully follow these
procedures may result in serious injury or death.
13. If these measurements at not met at ALL 6 locations the high voltage battery is not properly seated and should
be lifted, repositioned using tag lines and lowered again.
Danger: Measurements need to be retaken at all 6 locations to ensure fully seated. Failure to carefully follow these
procedures may result in serious injury or death.
14. Once above measurements are taken and it is confirmed the high voltage battery is fully seated, disconnect lifting
straps.
CAUTION: Ensure none of the high voltage battery “feet” are resting on any of the vertical supports to avoid high
voltage battery damage.
5903450
15. Once the high voltage battery is safely lowered into the crate, disconnect all six (eyenuts/bolts) assemblies from
the high voltage battery. Remove eyenuts/bolts and lifting harness off of the high voltage battery and out of full
cycle crate.
5903454
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16. Open second absorbent pad, place on top of the high voltage battery as shown on the picture below, tuck the
absorbent pad around the high voltage battery.
5903455
17. Fold the gusseted poly bag as follows:
a. Fold excess poly bag material on one short side of crate over end of high voltage battery.
b. Repeat for opposite short side of poly bag.
5903456
18. Fold excess poly bag material one of the long sides of crate across side of high voltage battery. Repeat for the
opposite long side of poly bag.
5903457
19. Loosely secure cinch straps take the 18 inch x 16 inch (46 x 41 cm) perforated absorbent pad, tear at perforation
and place (1) pad under each of the (2) buckles to prevent any chaffing, or tears on the poly bag. Pull (2) cinch
straps tight.
5903458
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20. Using the previously removed 16 x T20 or T25 Torx head screws, reattach (2) horizontal crossbars on each side
of the crate. Do not over tighten. Screws should be flush with top surface of the crossbar.
Important: DO NOT reinstall original lag screws securing the battery. Use extreme caution to ensure the poly
bag is not pierced or torn to ensure compliance with dangerous goods transportation laws.
Important: Place a copy of the repair order with the high voltage battery to be returned. Failure to return a copy
of the repair order with the shipment may result in a debit.
5903460
21. Return the lid to top of crate lifting by the handles on the top of the lid, ensure the HEAVY END on lid aligns
with heavy end on the side of the crate. Carefully attach the lid using the (12) 1/2 inch hex head x 5/16 inch
dia. x 4 inch lag screws that were loosened when the new battery was removed from the crate. Do not apply
more than the maximum torque of 84-117 in-lbs. (7 – 9.75 ft-lbs.) (.97 – 1.24 – kg-m).
5903461
5903462
22. Reverse the (2), Class 9 panels to read Damaged / Defective (one on each side of the crate).
23. Open the three (3) release clips and reverse the panel to show UN3480 – DAMAGE / DEFECTIVE side.
24. Close the three (3) clips to secure the panel in place.
5903463
25. Do not stack loaded crates more than 3 high. Maximum stacking weight 6,579 lbs. (2984kg). Ensure gross
package weight does not exceed the UN specification mark on the package of 1645 lbs. (746 KG).
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Important: Be sure to set up temporary location for the removed battery until final shipping preparation. Do not expose the crate to rain, snow or any other environment that will cause moisture related damage.
Ensure that all legal requirements for shipment of this material have been met, including those applicable to you as the shipper of dangerous goods/hazardous materials.
Contact and Website Information
Important: For assistance with any dangerous goods relating to packaging or shipping information, please contact the Dangerous Goods and Container Question Hotline (English, Spanish and French) at:
• 1 (844) 931-4966
• Hours of Operation – Monday through Friday 8 a.m. – 5 p.m. US Central Standard Time.
Please refer to your region’s GM Bulletin for the latest updates associated with this recall campaign. GM bulletins:
• N212343882 (export only)
• N212345942 (export only)
Important: The high voltage battery is regulated under dangerous goods transportation laws. As the shipper of record, dealers are responsible for compliance with all applicable international, federal, state, provincial, or local dangerous goods transportation laws. This includes, but is not limited to proper labeling, marking, completion of shipping papers, and packaging. Failure to comply with federal dangerous goods transportation laws may result in a violation of the U.S. Hazardous Materials Transportation Act, as amended, and its implementing regulations issued by the U.S. Department of Transportation at Title 49, Volumes 2-3, of the Code of Federal Regulations and could subject you to fines of up to $84,425 for each violation, or criminal penalties.
Dealer Responsibility – For USA & Export (USA States, Territories, and Possessions)
It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.
The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.
Dealer Responsibility – All
All new, used, GM Certified Used, courtesy transportation vehicles, dealer shuttle vehicles, etc. in dealers’ possession and subject to this recall must be held and inspected/repaired per the service procedure of this bulletin before customers take possession of these vehicles. Involved vehicles must be held and not delivered to customers, dealer-traded, released to auction, used for demonstration, or any other purpose.
All GM Certified Used vehicles currently in the dealers’ inventory within the Certified Pre-Owned Inventory System (CPOIS) will be de-certified and must be held and remedied per the service procedure in this bulletin. Upon submitting an accepted/paid warranty transaction in the Global Warranty Management (GWM) system, the vehicle can be re-certified for sale within the CPOIS system, or once again be used in the CTP program.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this field action enters your vehicle inventory you must take the steps necessary to ensure the program correction has been made before selling the vehicle. In addition, for vehicles entering
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your facility for service, you are required to ensure the customer is aware of the open field action and make every reasonable effort to implement the program correction as set forth in this bulletin prior to releasing the vehicle.
Dealer Reports
For dealers with involved vehicles, a listing has been prepared and will be available through GM GlobalConnect Maxis Field Action Reports or sent directly to export dealers. The Inventory tab of the dealer reports will contain VINs that apply to this recall. This information is intended to assist dealers with the PROMPT COMPLETION of these vehicles. The Customer In-Service tab will contain customer names and addresses from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall may be a violation of law in several states.
Courtesy Transportation – For USA & Canada
Courtesy transportation is available for customers whose vehicles are involved in this safety recall.
Customer Notification
USA & Canada – General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).
Export – Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.
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 tools, equipment, 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 dealer for information on whether your vehicle may benefit from the information.
We Support Voluntary Technician Certification
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IMPORTANT SAFETY RECALL
January 2022
This notice applies to your vehicle, VIN: _____________________________________
Dear General Motors Customer:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2017 – 2019 model year Chevrolet Bolt EV vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.
IMPORTANT
• Your vehicle is involved in GM safety recall N212343881.
• We have determined that the lithium ion battery modules in your vehicle should be replaced with new lithium ion battery modules.
• You should contact your Chevrolet EV certified dealer to arrange an appointment.
• This service will be performed for you at no charge.
• Until you have the service performed, we ask that you still follow our previous guidelines, which are outlined on our website: www.chevy.com/boltevrecall.
Why is your vehicle being recalled?
Your vehicle may have a lithium ion battery pack that may pose a risk of fire when charged to full, or very close to full, capacity.
What will we do?
Your Chevrolet EV certified dealer will replace the lithium ion battery modules in your vehicle with new lithium ion battery modules. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 4 hours and 30 minutes.
What should you do?
You should contact your Chevrolet EV certified dealer to arrange a service appointment as soon as possible. Until you have the service performed, we ask that you still follow our previous guidelines, which are outlined on our website: www.chevy.com/boltevrecall.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the Chevrolet EV Concierge team at 833-EVCHEVY (833-382-4389). Hours of operation are Monday through Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM to 9:00 PM ET.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 21V650.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Regina A. Carto
Vice President
Global Product Safety and Systems
GM Recall: N212343881
****************************************************************************************************************
Enclosed is a communication regarding a recall on your Bolt EV. At Chevrolet, it is our mission to keep you, our
customer, at the center of everything we do. To that end, we are writing you today to communicate the first
steps on how we will make good on that promise. Because safety is our highest priority, and in an abundance of
caution, we plan to replace the lithium-ion battery modules in your vehicle with new lithium-ion battery modules
as parts become available. These all-new lithium-ion battery modules will provide you with:
– All-new cells featuring GM’s most advanced Bolt chemistry
– 8% additional battery capacity, resulting in a vehicle range improvement in equivalent driving conditions*
– A new 8-year/100,000-mile Limited Parts Warranty for your lithium-ion battery upon completion of the
battery module replacement**
We understand that trust is earned and not given, and we are committed to regain your trust. This starts with
new lithium-ion battery modules and an experience that supports your needs. Central to that experience will be
repair status communications. Please ensure your information is up to date through the Chevrolet Owner Center
at my.chevrolet.com/recalls. We plan to communicate to make sure we do what we can to make this right for you.
Chevrolet’s transition to an all-electric future is predicated on our relentless desire to do the right thing, and I
want to thank you for putting your trust in our brand.
Steve Hill
Vice President, Chevrolet
* GM estimate. Actual range will vary based on several factors, including temperature, terrain, battery age, loading, use and maintenance.
** Whichever comes first. See Limited Parts Warranty for details.
**********************************************************************************************************
CHEVROLET
At Chevrolet it is our mission to keep you, our customer, at the center of everything we do. To that end, we are writing you today to
hear from Chevrolet directly about your vehicle. General Motors is voluntarily expanding the current Chevrolet Bolt EV recall to
cover the remaining 2019 and all 2020-2022 model year vehicles, including the Bolt EUV. In rare circumstances, LG batteries supplied
to GM for these vehicles may have manufacturing defects which increase the risk of fire. Out of an abundance of caution, GM will
replace the lithium ion battery modules in your vehicle with new lithium ion battery modules as parts become available. These allnew
lithium ion battery modules will provide you with:
All new cells featuring GM’s most advanced Bolt chemistry
8% additional battery capacity resulting in a vehicle range improvement in equivalent driving conditions*
A new 8-year / 100,000-mile limited parts warranty for your lithium ion battery upon completion of the battery module
replacement**
We are working aggressively with LG to increase production as soon as possible. We will notify you when replacement parts are
ready. For your safety we are asking for you to immediately do the following:
1. Set your vehicle to a 90 percent state of charge limitation using Target Charge Level mode. Instructions on how to do this
are available on (www.chevy.com/boltevrecall). If you are unable to successfully make these changes, or do not feel
comfortable making these changes, GM is asking you to visit your dealer to have these adjustments completed.
2. Charge your vehicle more frequently and avoid depleting your battery below approximately 70 miles (113 kilometers) of
remaining range, where possible.
3. Park your vehicle outside immediately after charging and do not leave your vehicle charging indoors overnight.
We understand that trust is earned and not given, and we are committed to regaining your trust. This starts with new lithium ion
battery modules and an experience that supports your needs. We know you have a lot of questions. Our team is working hard to get
you answers and we plan to be in regular communication. Please visit www.chevy.com/boltevrecall, contact the Chevrolet EV
Concierge 1-833-EVCHEVY (available Monday through Friday from 8 a.m.-midnight ET; Saturday and Sunday from noon-9 p.m. ET),
or contact your preferred Chevrolet EV dealer for the latest information.
Chevrolet’s transition to an all-electric future is predicated on our relentless desire to do the right thing, and I want to thank you for
putting your trust in our brand.
Steve Hill
Vice President, Chevrolet
*GM estimate. Actual range will vary based on several factors, including temperature, terrain, battery age, loading, use and maintenance.
**Whichever comes f irst. See limited parts warranty for details.
**********************************************************************************************************
REMINDER: SCHEDULE YOUR
FREE ADVANCED DIAGNOSTIC
SOFTWARE UPDATE NOW.
©2021 General Motors. All Rights Reserved. BSE
[Unique_ID] [Creative_Code]
[Date]


[FName],
Thanks again for your continued patience while the team at Chevrolet works as quickly as we can to provide you
with replacement battery modules for your Bolt EV. Battery replacements have begun, and we continue to work
with our battery supplier to obtain more battery modules to help speed up the replacement process.
We are pleased to inform you that we have developed an advanced diagnostic software package that will remove
parking and charging limitations on your 2019 vehicle while we work on building replacement battery modules.
This software will automatically limit your vehicle’s maximum charge to 80%, which will allow you
to safely resume:
This software also contains new diagnostics designed to detect specific abnormalities that might indicate a rare
battery issue in your vehicle.
THIS SOFTWARE IS NOW AVAILABLE FOR YOUR 2019 VEHICLE
Schedule a service appointment at your preferred Chevrolet EV dealer to have the software installed. The service
should take approximately 1–3 hours to complete. Until you have the software installed, we ask that you still follow
our previous guidelines, which are outlined on our website: www.chevy.com/boltevrecall.
This software is not the final recall remedy, and you will be notified when battery modules are available for
replacement. If you have already had this software update completed after November 2021, please disregard
this notice.
[DEALER_NAME]
[DLR_SERVICE_PHONE]
Once again, we appreciate your patience and understanding. If you have any questions, please contact the
Chevrolet EV Concierge at 1-833-EVCHEVY (1-833-382-4389) or your preferred Chevrolet EV dealer.
Sincerely,
Steve Hill
Vice President, Chevrolet
Charging indoors overnight
Depleting your vehicle’s battery below 70 miles (113 km) of range, resulting in greater overall
vehicle range compared to GM’s prior interim charging guidance; and
Parking • indoors after charging
RECORDATORIO: PROGRAME
AHORA SU ACTUALIZACIÓN
GRATUITA DE SOFTWARE DE
DIAGNÓSTICO AVANZADO.
©2021 General Motors. Todos los derechos reservados. BSS
[Unique_ID] [Creative_Code]
[Date]
Cargar bajo techo durante la noche
Agotar la batería de su vehículo por debajo de las 70 millas (113 km) de autonomía, dando como
resultado una mayor autonomía total del vehículo en comparación con las instrucciones
provisionales de GM para carga anteriores; y
Estacionar b • ajo techo después de la carga


[FName],
Gracias nuevamente por continuar brindándonos su paciencia, mientras el equipo de Chevrolet trabaja con la
mayor rapidez posible para proporcionarle módulos de batería de reemplazo para su Bolt EV. Ya iniciaron los
reemplazos de batería, y nosotros continuamos trabajando con nuestro proveedor de baterías para conseguir
más módulos de batería que nos ayuden a agilizar el proceso de reemplazo.
Nos complace informarle que hemos desarrollado un paquete de software de diagnóstico avanzado que eliminará
las limitaciones sobre estacionamiento y carga en su vehículo 2019, mientras trabajamos en producir módulos de
batería de reemplazo.
Este software limitará automáticamente la carga máxima de su vehículo al 80%, lo cual le permitirá
reanudar de manera segura:
Este software también contiene nuevo diagnóstico diseñado para detectar anormalidades específicas que
podrían indicar un problema inusual con la batería en su vehículo.
ESTE SOFTWARE YA ESTÁ DISPONIBLE PARA SU VEHÍCULO 2019
Programe una cita de servicio en su concesionario Chevrolet EV para que le instalen el software. El servicio debe
demorar aproximadamente de 1 a 3 horas. Hasta que le hayan instalado el software, le solicitamos que continúe
acatando nuestras pautas anteriores, las cuales se detallan en nuestro sitio web: www.chevy.com/boltevrecall.
Este software no es la solución definitiva de la llamada a revisión; usted recibirá una notificación cuando los
módulos de batería estén disponibles para el reemplazo. Si ya le instalaron esta actualización de software después
de noviembre de 2021, por favor ignore este aviso.
[DEALER_NAME]
[DLR_SERVICE_PHONE]
Una vez más, agradecemos su paciencia y su comprensión. Si tiene alguna pregunta, por favor póngase en
contacto con el Chevrolet EV Concierge al 1-833-EVCHEVY (1-833-382-4389) o con el concesionario Chevrolet EV
de su preferencia.
Atentamente,
Steve Hill
Vicepresidente, Chevrolet
**********************************************************************************************************
REMINDER: SCHEDULE YOUR
FREE ADVANCED DIAGNOSTIC
SOFTWARE UPDATE NOW.
©2022 General Motors. All Rights Reserved. BSE
[Unique_ID] [Creative_Code]
[Date]


[FName],
Thanks again for your continued patience while the team at Chevrolet works as quickly as we can to provide you
with replacement battery modules for your Bolt EV. Battery replacements have begun, and we continue to work
with our battery supplier to obtain more battery modules to help speed up the replacement process.
We are pleased to inform you that we have developed an advanced diagnostic software package that will remove
parking and charging limitations on your vehicle while we work on building replacement battery modules.
This software will automatically limit your vehicle’s maximum charge to 80%, which will allow you
to safely resume:
This software also contains new diagnostics designed to detect specifi c abnormalities that might indicate a rare
battery issue in your vehicle.
THIS SOFTWARE IS NOW AVAILABLE FOR YOUR VEHICLE
Schedule a service appointment at your preferred Chevrolet EV dealer to have the software installed. The service
should take approximately 1–3 hours to complete. Until you have the software installed, we ask that you still follow
our previous guidelines, which are outlined on our website: www.chevy.com/boltevrecall.
This software is not the fi nal recall remedy, and you will be notifi ed when battery modules are available for
replacement. If you have already had this software update completed after November 2021, please disregard
this notice.
[DEALER_NAME]
[DLR_SERVICE_PHONE]
Once again, we appreciate your patience and understanding. If you have any questions, please contact the
Chevrolet EV Concierge at 1-833-EVCHEVY (1-833-382-4389) or your preferred Chevrolet EV dealer.
Sincerely,
Steve Hill
Vice President, Chevrolet
Charging indoors overnight
Depleting your vehicle’s battery below 70 miles (113 km) of range, resulting in greater overall
vehicle range compared to GM’s prior interim charging guidance; and
Parking i • ndoors after charging
012022
9999101 CSN
1
Sam Sample,
Sample Dealer
(123) 456-7891
RECORDATORIO: PROGRAME
AHORA SU ACTUALIZACIÓN
GRATUITA DE SOFTWARE DE
DIAGNÓSTICO AVANZADO.
©2022 General Motors. Todos los derechos reservados. BSS
[Unique_ID] [Creative_Code]
[Date]
Cargar bajo techo durante la noche
Agotar la batería de su vehículo por debajo de las 70 millas (113 km) de autonomía, dando como
resultado una mayor autonomía total del vehículo en comparación con las instrucciones
provisionales de GM para carga anteriores; y
Estacionar b • ajo techo después de la carga


[FName],
Gracias nuevamente por continuar brindándonos su paciencia, mientras el equipo de Chevrolet trabaja con la
mayor rapidez posible para proporcionarle módulos de batería de reemplazo para su Bolt EV. Ya iniciaron los
reemplazos de batería, y nosotros continuamos trabajando con nuestro proveedor de baterías para conseguir
más módulos de batería que nos ayuden a agilizar el proceso de reemplazo.
Nos complace informarle que hemos desarrollado un paquete de software de diagnóstico avanzado que eliminará
las limitaciones sobre estacionamiento y carga en su vehículo, mientras trabajamos en producir módulos de
batería de reemplazo.
Este software limitará automáticamente la carga máxima de su vehículo al 80%, lo cual le permitirá
reanudar de manera segura:
Este software también contiene nuevo diagnóstico diseñado para detectar anormalidades específi cas que
podrían indicar un problema inusual con la batería en su vehículo.
ESTE SOFTWARE YA ESTÁ DISPONIBLE PARA SU VEHÍCULO
Programe una cita de servicio en su concesionario Chevrolet EV para que le instalen el software. El servicio debe
demorar aproximadamente de 1 a 3 horas. Hasta que le hayan instalado el software, le solicitamos que continúe
acatando nuestras pautas anteriores, las cuales se detallan en nuestro sitio web: www.chevy.com/boltevrecall.
Este software no es la solución defi nitiva de la llamada a revisión; usted recibirá una notifi cación cuando los
módulos de batería estén disponibles para el reemplazo. Si ya le instalaron esta actualización de software después
de noviembre de 2021, por favor ignore este aviso.
[DEALER_NAME]
[DLR_SERVICE_PHONE]
Una vez más, agradecemos su paciencia y su comprensión. Si tiene alguna pregunta, por favor póngase en
contacto con el Chevrolet EV Concierge al 1-833-EVCHEVY (1-833-382-4389) o con el concesionario Chevrolet EV
de su preferencia.
Atentamente,
Steve Hill
Vicepresidente, Chevrolet
012022
9999101 CSN
1
Sam Sample,
Sample Dealer
(123) 456-7891
GM Vehicle Safety
PO Box 3047
Milwaukee, WI 53201
PRESORTED
FIRST-CLASS MAIL
U.S. POSTAGE
PAID
GENERAL MOTORS
IMPORTANT:
BOLT EV RECALL INFORMATION ENCLOSED.
********************AUTO**MIXED AADC 480 T1 P1
4 CSN 393
Anabella Sarubbi-Monaco
384 Main St
Winsted, CT 06098-1640
**********************************************************************************************************
GM CUSTOMER CARE AND AFTERSALES
DCS5884
URGENT – DISTRIBUTE IMMEDIATELY
Date: July 30, 2021
Updated Bolt EV Recall Statement:
To: Chevrolet Bolt EV & Bolt EUV Dealers in North America
Bolt EV & Bolt EUV lithium ion batteries for all model years for service are temporarily on hold. At this time the GM Battery Service Center and York Electronics are taking orders but will not ship. Other vehicle models are unaffected. An updated message will be sent when the situation changes.
END OF MESSAGE
General Motors Company
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5937
URGENT – DISTRIBUTE IMMEDIATELY
Date: September 20, 2021
Subject: Chevrolet Bolt Battery Safety Recall Update
Models: 2017 – 2022 Chevrolet Bolt EV and EUV
To: All General Motors Dealers
Chevrolet Bolt EV Battery Production Resumes
• LG battery cell and module production resumes with updated manufacturing processes
• Battery module replacements to begin in October
• GM to introduce new advanced diagnostics software
DETROIT – General Motors today outlined a comprehensive action plan to ensure that customers can safely and confidently drive, charge, and park the Chevy Bolt EV and EUV. The action plan includes both hardware and software remedies, some of which are in place with immediate effect.
“We’re grateful for the patience of owners and dealers as we work to advance solutions to this recall,” said Doug Parks, GM executive vice president, Global Product Development, Purchasing and Supply Chain. “Resuming battery module production is a first step and we’ll continue to work aggressively with LG to obtain additional battery supply. In addition, we’re optimistic a new advanced diagnostic software will provide more convenience for our customers.”
New Battery Production
LG battery plants in Holland and Hazel Park, Michigan, have resumed production. In addition, LG is adding capacity to provide more cells to GM. As a result, replacement battery modules will begin shipping to dealers as soon as mid-October.
The root cause of the rare circumstances that could cause a battery fire is two manufacturing defects known as a torn anode and a folded separator, both of which need to be present in the same battery cell.
LG has implemented new manufacturing processes and has worked with GM to review and enhance its quality assurance programs to provide confidence in its batteries moving forward. LG will institute these new processes in other facilities that will provide cells to GM in the future.
Prioritized Battery Replacement
GM will continue to prioritize Chevy Bolt EV and EUV customers whose batteries were manufactured during specific build timeframes where GM believes battery defects appear to be clustered. The company has established a notification process that will inform affected customers when their replacement modules will be available.
The new batteries will include an extended battery 8-year/100,000-mile limited warranty.
New Advanced Diagnostic Software
Within approximately 60 days, GM will begin launching a new advanced diagnostic software package that will increase the available battery charging parameters over existing guidance.
The diagnostic software will be designed to detect specific abnormalities that might indicate a damaged battery in Bolt EVs and EUVs by: monitoring the battery performance; alerting customers of any anomalies; and prioritizing damaged battery modules for replacement. It is GM’s intent that further diagnostic software will allow customers to return to a 100 percent state of charge once all diagnostic processes are complete.
This new software, which will be provided to all Bolt EV and EUV owners, requires dealer installation. Owners will be able to start to schedule installation at their Chevy EV dealer in approximately 60 days.
Updated Guidance on Parking
If customers are following GM’s instructions issued below, they can park in a location of their choice. In an abundance of caution, GM recommends customers leave ample space around their vehicle wherever they choose to park. GM is not aware of any fires that have occurred where customers followed this safety guidance, in parking decks or otherwise.
GM’s instructions remain:
1. Set the vehicle to a 90 percent state of charge limitation using Target Charge Level mode. Instructions on how to do this are available on chevy.com/boltevrecall. If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their dealer to have these adjustments completed.
2. Charge the vehicle more frequently and avoid depleting battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park vehicles outside immediately after charging and do not leave vehicles charging indoors overnight.
Customers who have additional questions can visit www.chevy.com/boltevrecall or contact the Chevrolet EV Concierge 1-833-EVCHEVY (available Monday through Friday, from 8 a.m. – midnight ET; Saturday and Sunday, from noon – 9 p.m. ET) or contact their preferred Chevrolet EV dealer.
General Motors (NYSE:GM) is a global company focused on advancing an all-electric future that is inclusive and accessible to all. At the heart of this strategy is the Ultium battery platform, which will power everything from mass-market to high-performance vehicles. General Motors, its subsidiaries and its joint venture entities sell vehicles under the Chevrolet, Buick, GMC, Cadillac, Baojun and Wuling brands. More information on the company and its subsidiaries, including OnStar, a global leader in vehicle safety and security services, can be found at https://www.gm.com.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
IMPORTANT SAFETY RECALL
August 2021
This notice applies to your vehicle, VIN: __________________________________
Dear General Motors Customer:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2017-2019 model year Chevrolet Bolt EV vehicles. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.
IMPORTANT
• Your vehicle is involved in GM safety recall N212343881.
• Based on manufacturing records, we have identified your vehicle battery as one built within a date range scheduled for priority repair under this recall.
• We have determined that the lithium ion battery modules in your vehicle should be replaced with new lithium ion battery modules.
• We are pleased to inform you we will have parts available to begin repairs by the end of August.
• You should contact your Chevrolet EV certified dealer on or after August 23 to arrange an appointment.
• This service will be performed for you at no charge.
Why is your vehicle being recalled?
Certain vehicles were built with high voltage cells produced at LG Chem’s Ochang, Korea facility that pose a risk of fire when charged to full, or very close to full, capacity. Experts from GM and LG have identified the simultaneous presence of two manufacturing defects in the same battery cell as the root cause of these battery fires.
What will we do?
Your GM dealer will replace the lithium ion battery modules in your vehicle with new lithium ion battery modules. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 3 hours 30 minutes.
What should you do?
Until this recall repair is performed, you should take the following interim steps:
1. You should, whether or not your vehicle received the recall remedy in GM safety recall N202311731, return your vehicle to the 90% state of charge limitation using Hilltop Reserve
mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. If you are unable to successfully make these changes, or do not feel comfortable making these changes, visit your Chevrolet EV dealer to have these adjustments completed, free of charge.
2. Charge your vehicle more frequently and avoid depleting your battery below approximately 70 miles (113 KM) of remaining range, where possible.
3. Continue to park your vehicle outside immediately after charging and do not leave your vehicle charging indoors overnight.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the Chevrolet EV Concierge team at 833-EVCHEVY (833-382-4389). Hours of operation are Monday through Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM to 9:00 PM ET.
If after contacting your dealer and the Chevrolet EV Concierge, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 21V560.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Regina Carto
Vice President
Global Vehicle Safety and Systems
GM Recall: N212343881
**********************************************************************************************************
IMPORTANT SAFETY RECALL
September 2021
This notice applies to your vehicle, VIN: __________________________________
Dear General Motors Customer:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2017-2019 model year Chevrolet Bolt vehicles. As a result, GM is conducting a safety recall. We understand the inconvenience this recall has placed on you, and we sincerely apologize for that. We want to thank you for putting your trust in our brand, and know that we will continue to work hard to earn that trust.
IMPORTANT
• Your vehicle is involved in GM recall N212343881.
• Based on manufacturing records, we have identified your vehicle battery as one built within a date range scheduled for priority repair under this recall.
• We have determined that the lithium ion battery modules in your vehicle should be replaced with new lithium ion battery modules.
• You should contact your Chevrolet EV certified dealer to arrange an appointment.
• This service will be performed for you at no charge.
• This letter contains important interim safety precautions that should be followed until the final recall remedy is performed on your vehicle.
Why is your vehicle being recalled?
Your vehicle may have a lithium ion battery pack that may pose a risk of fire when charged to full, or very close to full, capacity.
What will we do?
Your Chevrolet EV certified dealer will replace the lithium ion battery modules in your vehicle with new lithium ion battery modules. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 4 hours and 30 minutes.
What should you do?
You should contact your Chevrolet EV certified dealer to arrange a service appointment as soon as possible. In the meantime, you should continue following these steps:
1. Set your vehicle to a 90 percent state of charge limitation. Instructions on how to do this are available on www.chevy.com/boltevrecall. If you are unable to successfully make these changes, or do not feel comfortable
making these changes, GM is asking you to visit your dealer to have these adjustments completed, free of charge.
2. Charge your vehicle more frequently and avoid depleting your battery below approximately 70 miles (113 KM) of remaining range, where possible.
3. Continue to park your vehicle outside immediately after charging and do not leave your vehicle charging indoors overnight.
Do you have questions?
If you have questions or concerns that your dealer is unable to resolve, please contact the Chevrolet EV Concierge team at 833-EVCHEVY (833-382-4389). Hours of operation are Monday through Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM to 9:00 PM ET.
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National Highway Traffic Safety Administration Campaign ID Number for this recall is 21V560.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Regina Carto
Vice President
Global Vehicle Safety and Systems
GM Recall N212343881
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6003
URGENT – DISTRIBUTE IMMEDIATELY
Date: December 15, 2021
Subject: N212343883-01 – Safety Recall for 2017-2019MY Chevrolet Bolt EV Vehicles involved in N212343880 – High Voltage Battery May Melt or Burn – REVISION
Includes Advanced Diagnostic Software Package.
2017-2018 model year vehicles added.
Models: 2017-2019MY Chevrolet Bolt EV
To: All General Motors Dealers
2017-2018 model year vehicles have been added and the programming steps of the service procedure in this bulletin have been revised. Please discard all previous copies of bulletin N212343883.
General Motors has developed an advanced diagnostic software package in N212343883-01 that will remove parking and charging limitations on 2017-2019 MY Chevrolet Bolt EV vehicles that have not yet received their replacement battery module. This software is not the final remedy, and customers will be notified when battery modules are available for replacement under Safety Recall N212343881.
The new software automatically sets the vehicle’s maximum state of charge to 80%, allowing owners to safely resume:
• charging indoors overnight;
• depleting their vehicle’s battery below 70 miles (113 km) of range, resulting in greater overall vehicle range compared to GM’s prior interim charging guidance; and,
• parking indoors after charging.
This software also contains new diagnostics designed to detect specific abnormalities that might indicate a rare battery issue in the vehicle.
IMPORTANT: The information referenced in this message contains a service procedure that WILL NOT close the recall. The status of the recall will remain “Incomplete, Remedy Not Available” in the Investigate Vehicle History (IVH) section of Global Warranty Management even after the completion of the service procedure. Dealers should submit warranty claims for affected vehicles after the procedure in bulletin N212343883 is successfully completed.
This recall must only be completed by Chevrolet EV certified dealers who have met all Bolt recall-specific training, tool and equipment requirements. Repairs must be performed by a technician who has successfully completed the required training. Any dealership unsure of their eligibility status should review with their District Service Manager.
Question and Answer Document (Q&A)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on November 19, 2021.
Global Warranty Management (GWM)
The Required Field Action section on the Investigate Vehicle History (IVH) screen will be updated December 15, 2021. The VINs will have a status of “Incomplete-Remedy Not Available”. Dealers should submit warranty claims for affected vehicles after the procedure in bulletin N212343883 is successfully completed.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6083
URGENT – DISTRIBUTE IMMEDIATELY
Date: March 15, 2022
Subject: N212343881-03 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On March 14, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5980
URGENT – DISTRIBUTE IMMEDIATELY
Date: November 8, 2021
Subject: N212343881-01 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for repair, they will be closed in N212343880 and moved into N212343881. All other VINs will remain in “Incomplete-Remedy Not Available” status under N212343880 and will not be eligible for the final repair until GM informs dealers at a future date. WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until recall repairs can be completed, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
To avoid warranty transaction rejections, dealers MUST record the warranty claim code provided on the Warranty Claim Code (WCC) screen. Labor code 9105785 – ZFA – Field Action Multimodule Coordinated Sequence MUST also be used, or the claim will reject.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On November 5th, additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
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GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5955
URGENT – DISTRIBUTE IMMEDIATELY
Date: October 07, 2021
Subject: N212343881 – Safety Recall
High Voltage Battery May Melt or Burn
Models: 2017-19MY Chevrolet Bolt EV
To: All General Motors Dealers
General Motors is releasing Safety Recall N212343881 today. Initially, this bulletin will only be applied to a small population of vehicles with batteries that were manufactured during specific build timeframes where GM believes battery defects appear to be clustered. Customer owned vehicles currently awaiting repair after failing either the on-board or dealer battery module diagnostics will also be eligible for repair. Please see the attached bulletin for details.
VINs being made eligible for repair will be closed in N212343880 and moved into N212343881. In addition, the field action status will be changed to “open” on the Investigate Vehicle History (IVH) screen in Global Warranty Management. All other VINs will remain in “Incomplete-Remedy Not Available” status in N212343880 and will not be eligible for the final repair until GM informs dealers at a future date.
When making customer appointments, please advise owners it not necessary to charge their high voltage battery the day before their appointment if the vehicle has sufficient charge to reach the dealership.
Until recall repairs can be completed, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
Only Chevrolet EV certified dealers meeting all the Bolt-specific training, tools, and equipment requirements are eligible to complete recall repairs (see GCUS-9-11935 and GCUS-9-11959 for details). Part orders will be rejected until all requirements have been met. Any dealership unsure of their eligibility status should immediately review with their District Manager of Aftersales or District Service Manager.
In addition to the training and tool requirements necessary to complete the service procedures in these recalls, one of the following is required to safely and adequately unload and load battery pack crates from and to the delivery truck:
1. Stand-up, sit-down or walkie forklifts capable of lifting a minimum lifting capacity of 3,000 pounds *
• 60″ forks (48″ are acceptable for already existing forklifts; fork extensions that offer the same capacity are recommended)
• At least one trained employee that is forklift certified in accordance with local, state, provincial, and federal regulations
• Ample space to maneuver the forklift between service bays
2. Loading/Unloading Docks are acceptable if available
• Pallet Jack with 3000-pound capacity or larger and 48-60″ forks with a separation of 20″
• Dock wells with grades exceeding 10% require a forklift, no pallet jacks allowed
* Please note, future EV models, including the All Electric Silverado, will require an 8,000-pound capacity forklift with 72″ forks
Courtesy Transportation Program
Dealers seeking to assist Bolt owners with rental vehicles should verify with Hertz for available vehicles in support of our rates. Refer to the GM Courtesy Transportation bulletin 07-00-89-037 in GlobalConnect for details.
Question and Answer Document (Q&A)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns
Working Capital Assistance Program (WCAP) Eligibility
Vehicles which were in dealer inventory at the time of this bulletin release were eligible for WCA. Please refer to the attached bulletin and GlobalConnect Message GCUS-9-9188 for additional information.
Customer Letter Mailing
The customer letter mailing began mailing on October 06, 2021 for the highest priority group.
Global Warranty Management (GWM)
The Required Field Action section on the Investigate Vehicle History (IVH) screen will be updated October 07, 2021. Please hold all warranty transactions until IVH has been updated.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6036
URGENT – DISTRIBUTE IMMEDIATELY
Date: January 25, 2022
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On January 24, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
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IMPORTANT: High Voltage Battery Cooling System Draining – Safety Recalls N212343881 and N212345941 Updated Date: Dec 16, 2021 11:30 CT GLOBAL SAFETY FIELD INVESTIGATIONS DCS6007 URGENT – DISTRIBUTE IMMEDIATELY Date: December 16, 2021 Subject: IMPORTANT: High Voltage Battery Cooling System Draining Safety Recalls N212343881 and N212345941 Models: 2019-2022 Model Year Chevrolet Bolt EV/EUV To: All General Motors Dealers We are experiencing an increased number of Chevrolet Bolt EV/EUV high voltage batteries returned under Safety Recall N212343881 and N212345941 where the coolant has not been completely drained from the battery. Prior to being removed from the vehicle, the high voltage battery must be completely drained of coolant using the Vac-N-Fill Procedure. Static draining is not sufficient. Please refer to the Drive Motor Battery Cooling System Draining and Filling in SI (Document ID: 4499122). END OF MESSAGE GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6043
URGENT – DISTRIBUTE IMMEDIATELY
Date: February 1, 2022
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On January 31, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6072
URGENT – DISTRIBUTE IMMEDIATELY
Date: March 8, 2022
Subject: N212343881-03 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On March 7, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5996
URGENT – DISTRIBUTE IMMEDIATELY
Date: December 6, 2021
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Multiple sections have been revised including the emphasis on ZFA Multimodule Coordinated Sequence and Vac-N-Fill procedure; Additional vehicles have been moved to ‘Open’ status.
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
This bulletin has been revised in multiple areas, including to emphasize the importance of following the ZFA-Field Action Multimodule Coordinated Sequence and the importance of using the Vac-N-Fill procedure. Please take the time to re-read the entire bulletin thoroughly. Please discard all previous copies of bulletin N212343881.
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for final repair in N212343881, they will be closed in N212343880 or N212343883. Remaining VINs in “Incomplete-Remedy Not Available” status under N212343880 and N212343883 will not be eligible for the final repair until GM informs dealers at a future date. WCAP is calculated from the “Release Date” on VINs in “Open” Status in N212343881 in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until recall repairs can be completed, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On December 3rd, additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5898
URGENT – DISTRIBUTE IMMEDIATELY
Date: August 13, 2021
Subject: N212343880 / N212343881 – Safety Recall
High Voltage Battery May Melt or Burn
Models: Select 2017-19MY Chevrolet Bolt EV
To: All General Motors Dealers
General Motors wants to provide our Chevrolet EV Certified Dealers with an
update regarding previously announced Bolt EV safety recall N212343880.
We informed dealers of this recall on July 23rd, 2021, at which time vehicles
involved in this recall were placed on stop delivery.
We have been working very diligently over the past weeks on a recall remedy
plan. We are rapidly approaching the release of a final remedy bulletin
N212343881. Initially, this bulletin will only be applied to a sub-set of highest
priority vehicles. When the final remedy bulletin is released, we will send a
Global Connect message informing dealers. We expect the final remedy
bulletin to be released late this month. When the final remedy bulletin is
released, the high priority sub-set of VINs will be closed in N212343880 and
moved into N212343881. In addition, the status will be changed to “open” on
the Investigate Vehicle History (IVH) screen in Global Warranty Management.
In the meantime, we are in the process of sending owner letters to the
customers involved in this recall. PDF versions of two different owner letters
are attached to this Global Connect message for your reference.
• The “Advisory” letter will be sent to all vehicle owners not initially included
in the highest priority group.
• The “Remedy” letter will be sent to all vehicle owners included in the
highest priority group. The “Remedy” letter informs owners they can begin
contacting their Chevrolet EV Certified Dealer on or after August 23rd to
begin scheduling appointments.
• Please do not schedule any appointments earlier than the week
beginning August 30th.
• If you are a Chevrolet EV Certified Dealer, but DO NOT have at least one
technician 100% EV trained, all necessary tools to remove/install a Bolt EV
battery, and a functional level 2 fast charger, YOU ARE NOT ELIGIBLE
TO PERFORM THIS REPAIR.
Please refer any customer that contacts you to the Chevrolet EV Concierge
team at 833-EVCHEVY (833-382-4389) where we will help direct that
customer to an eligible servicing dealer. Hours of operation are Monday
through Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM
to 9:00 PM ET.
As battery inventories increase, additional VINs will be moved from
N212343880 to N212343881 for the final remedy. We will inform dealers
through Global Connect messages when additional VINs become eligible for
the final repair.
The customer letters will begin mailing to owners in the United States on
August 13th, 2021.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
IMPORTANT SAFETY RECALL
August 2021This notice applies to your vehicle, VIN: .
Dear :
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect which relates to motor vehicle safety exists in certain
model year vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
I M P O R T A N T
• Your vehicle is involved in GM safety recall N212343880.
• Based on manufacturing records, we have identified your vehicle
battery as one built within a date range scheduled for priority
repair under this recall.
• We have determined that the lithium ion battery modules in your
vehicle should be replaced with new lithium ion battery modules.
• We are pleased to inform you we will have parts available to begin
repairs by the end of August.
• You should contact your Chevrolet EV certified dealer on or
after August 23 to arrange an appointment.
• This service will be performed for you at no charge.
Why is your
vehicle being
recalled?
Certain vehicles were built with high voltage cells produced at LG
Chem’s Ochang, Korea facility that pose a risk of fire when charged
to full, or very close to full, capacity. Experts from GM and LG have
identified the simultaneous presence of two manufacturing defects
in the same battery cell as the root cause of these battery fires.
What will we
do?
Your dealer will replace the lithium ion battery modules
in your vehicle with new lithium ion battery modules. This service
will be performed for you at no charge. Because of service
scheduling requirements, it is likely that your dealer will need your
vehicle longer than the actual service correction time of
approximately 3 hours 30 minutes.
What should
you do?
Until this recall repair is performed, you should take the
following interim steps:
1. You should, whether or not your vehicle received the recall
remedy in GM safety recall N202311731, return your vehicle
to the 90% state of charge limitation using Hilltop Reserve
mode (for 2017-2018 model years) or Target Charge Level (for
2019 model year) mode. If you are unable to successfully
make these changes, or do not feel comfortable making these
changes, visit your Chevrolet EV dealer to have these
adjustments completed, free of charge.
2. Charge your vehicle more frequently and avoid depleting your
battery below approximately 70 miles (113 KM) of remaining
range, where possible.
3. Continue to park your vehicle outside immediately after
charging and do not leave your vehicle charging indoors
overnight.
Do you have
questions?
If you have questions or concerns that your dealer is unable to
resolve, please contact the Chevrolet EV Concierge team at 833-
EVCHEVY (833-382-4389). Hours of operation are Monday through
Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM
to 9:00 PM ET.
If after contacting your dealer and the Chevrolet EV Concierge, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you
may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at
1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National
Highway Traffic Safety Administration Campaign ID Number for this recall is 21V560.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a
copy of this notice to the lessee within ten days.

GM Recall: N212343880
IMPORTANT SAFETY RECALL
August 2021

This notice applies to your vehicle, VIN: .
Dear :
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect which relates to motor vehicle safety exists in certain
model year vehicles. As a result, GM is
conducting a safety recall. We apologize for this inconvenience. However, we are concerned
about your safety and continued satisfaction with our products.
I M P O R T A N T
• Your vehicle is involved in a new GM safety recall N212343880.
• Previously, you were notified that your vehicle is involved in GM
recall N202311731. If you have not done so, you should visit your
Chevrolet EV dealer to obtain the remedy for the previous recall,
which includes an important software update and diagnostic check
on the health of your vehicle’s battery system.
• This letter contains important interim safety precautions that should
be followed until the final recall remedy for new recall number
N212343880 is performed on your vehicle.
Why is your
vehicle being
recalled?
Certain vehicles were built with high voltage cells produced at LG
Chem’s Ochang, Korea facility that pose a risk of fire when charged
to full, or very close to full, capacity. Experts from GM and LG have
identified the simultaneous presence of two manufacturing defects
in the same battery cell as the root cause of these battery fires.
What will we
do?
Parts to repair your vehicle are not currently available, but when
parts are available, your dealer will replace the lithium
ion battery modules in your vehicle with new lithium ion battery
modules. This service will be performed for you at no charge.
We are working as quickly as possible to correct this condition.
When parts are available, we will send you another letter asking you
to take your vehicle to your dealer to have your vehicle
serviced. You can also check the status of this recall at:
https://my.gm.com/recalls.
What should
you do?
While we prepare to conduct this recall, you should take the
following interim steps:
1. You should, whether or not your vehicle received the recall
remedy in GM safety recall N202311731, return your vehicle
to the 90% state of charge limitation using Hilltop Reserve
mode (for 2017-2018 model years) or Target Charge Level (for
2019 model year) mode. If you are unable to successfully
make these changes, or do not feel comfortable making these
changes, visit your Chevrolet EV dealer to have these
adjustments completed, free of charge.
2. Charge your vehicle more frequently and avoid depleting your
battery below approximately 70 miles (113 KM) of remaining
range, where possible.
3. Continue to park your vehicle outside immediately after
charging and do not leave your vehicle charging indoors
overnight.
If you have not visited your dealer to receive the recall remedy in
GM safety recall N202311731, you should visit your Chevrolet EV
dealer to obtain this important software update, which includes a
diagnostic check on the health of your vehicle’s battery system.
After obtaining the software update, you should still take the interim
steps summarized above. When scheduling your appointment,
confirm with the dealer that they are an EV certified dealer.
Do you have
questions?
If you have questions or concerns that your dealer is unable to
resolve, please contact the Chevrolet EV Concierge team at 833-
EVCHEVY (833-382-4389). Hours of operation are Monday through
Friday, 8:00 AM to 12:00 AM ET or Saturday and Sunday, 12:00 PM
to 9:00 PM ET.
If after contacting your dealer and the Chevrolet EV Concierge, you are still not satisfied we
have done our best to remedy this condition without charge and within a reasonable time, you
may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at
1.888.327.4236 (TTY 1.800.424.9153), or go to https://www.safercar.gov. The National
Highway Traffic Safety Administration Campaign ID Number for this recall is 21V560.
Federal regulation requires that any vehicle lessor receiving this recall notice must forward a
copy of this notice to the lessee within ten days.

GM Recall: N212343880
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6068
URGENT – DISTRIBUTE IMMEDIATELY
Date: March 3, 2022
Subject: N212343881-03 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On March 2, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6031
URGENT – DISTRIBUTE IMMEDIATELY
Date: January 19, 2022
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On January 14, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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3/8/22, 7:24 AM Document ID: 5919260
DocumentlD:5919260
#21-NA-261: Charge Limited to 80% After Battery Pack
Replaced for Recall N212343881 or N212345941 – {Mar 7,
2022)
Subject: Charge Limited to 80% After Battery Pack Replaced for Recall
N212343881 or N212345941 e
Model Year: VIN:
Brand: Model: Engine: Transmissi1 • n:
from to from to
Bolt EV 2017 2022
Chevrolet – – All All
Bolt EUV 2022 2022
Involved Region or Country United States, Canada, Middle East, GM Korea Company
Note: Read and compare these field action numbers carefully to
the vehicle in question.
Condition Some customers may comment that their vehicle stops charging
at 80% state of charge after a new battery pack was replaced for
recall N212343881 or N212345941.
The cause of the condition is that a VIN reconfiguration may be
Cause needed in Service Programming to align the vehicle with a 100%
state of charge calibration in the HPCM2.
Contact Techline at 800.828.6860 (English) (US & Canada)
Correction (800.503.3222 (French) with this bulletin number, VIN, and when
the battery pack was replaced (must be after 10/7/2021).
Warrantv. Information
Note: Claims must be submitted as ZFAT type.
Labor Use for Model Description Labor Time Operation Years
N212343881 – Remove Charge
9106052 2017-2019
Limit to 80 percent after Battery
1.0 hr
Pack replacement using Service
Bulletin 21-NA-261
© 2022 General Motors. All rights reserved.
https://gsitlc.ext.gm.com/gsi/showDoc.do?releaseDate=2022-03-07&name=Charge Limited to 80%25 After Battery Pack Replaced for Recall N212343… 1/2
3/8/22, 7:24 AM Document ID: 5919260
Labor Use for Model Operation Years Description Labor Time
N212345941 – Remove Charge
9106053 2020-2022 Limit to 80 percent after Battery
Pack replacement using Service 1.0 hr
Bulletin 21-NA-261
Version 2
Modified
Released November 12, 2021
March 07, 2022 – Added Warranty Information.
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.
© 2022 General Motors. All rights reserved.
0. WESUPPORT
VOLUNTARY
TECHNICIAN
CERTIFICATION
https://gsitlc.ext.gm.com/gsi/showDoc.do?releaseDate=2022-03-07&name=Charge Limited to 80%25 After Battery Pack Replaced for Recall N212343… 2/2
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6123
URGENT – DISTRIBUTE IMMEDIATELY
Date: April 13, 2022
Subject: N212343881-04 Safety Recall – REVISION
High Voltage Battery May Melt or Burn
High Voltage Battery Part Numbers have been removed from the Parts Table
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
This bulletin has been revised in the following areas:
• The High Voltage Battery part numbers have been removed from the Parts Table.
• The Battery Service Center will provide the appropriate High Voltage Battery part number based on the requested VIN.
• The VIN on the Bill of Lading needs to be verified to exactly match the VIN of the vehicle.
Please discard all previous copies of bulletin N212343881.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the Advanced Diagnostic Software package, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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Update – N212343880 / N212345940 – Safety Recall – High Voltage Battery May Melt or Burn Updated Date: Sep 28, 2021 15:30 CT Models: 2017-19MY Chevrolet Bolt EV 2020-22MY Chevrolet Bolt EV 2022MY Chevrolet Bolt EUV To: All General Motors Dealers General Motors is providing our Chevrolet EV Certified Dealers with an update regarding previously announced Bolt EV/EUV safety recalls N212343880 and N212345940. We have been working very diligently on a recall remedy plan and are rapidly approaching the release of our final remedy bulletins (N212343881 and N212345941). Initially, these bulletins will only be applied to a small subset of highest priority vehicles. Customer owned vehicles currently awaiting repair after failing either the on-board or dealer battery module diagnostics will also be eligible for repair when these final remedy bulletins are released. Upon bulletin release, the high priority subset of VINs will be closed in N212343880 (17-19MY) and N212345940 (20-22MY) and moved into N212343881 and N212345941, respectively. In addition, the Field Action status will be changed to “open” on the Investigate Vehicle History (IVH) screen in Global Warranty Management. All other VINs will remain in “Incomplete-Remedy Not Available” status in N212343880 (17-19MY) and N212345940 (20-22MY) and will not be eligible for the final remedy until GM informs dealers at a future date. We expect the final remedy bulletins to be released mid-October or sooner. It is a violation of federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification until the defect is remedied.
IMPORTANT
Only Chevrolet EV certified dealers meeting all the Bolt-specific training, tools, and equipment requirements are eligible to complete recall repairs (see attachments). Part orders will be rejected until all requirements have been met. Any dealership unsure of their eligibility status should immediately review with their District Manager of Aftersales or District Service Manager.
1. For assistance with required tools or equipment, please contact:
• Special Service Tools: 800-GM-TOOLS
• GM Dealer Equipment: 844-742-8471
In addition to the training and tool requirements necessary to complete the service procedures in these recalls, one of the following is required to safely and adequately unload and load battery pack crates from and to the delivery truck:
1. Stand-up, sit-down or walkie forklifts capable of lifting a minimum lifting capacity of 3,000 pounds*
• 60″ forks (48″ are acceptable for already existing forklifts; fork extensions that offer the same capacity are recommended)
• At least one trained employee that is forklift certified in accordance with local, state, provincial, and federal regulations
• Ample space to maneuver the forklift between service bays
2. Loading/Unloading Docks are acceptable if available
• Pallet Jack with 3000-pound capacity or larger and 48-60″ forks with a separation of 20″
• Dock wells with grades exceeding 10% require a forklift, no pallet jacks allowed
* Please note, future EV models, including the All Electric Silverado, will require an 8,000-pound capacity forklift with 72″ forks.
To assist dealers in the United States and Canada with an offset to the financial impacts related to throughput, technician efficiency, battery handling and storage, BDC, tools and equipment (including forklifts) associated with this recall, dealers will be paid an additional $600 allowance
with each warranty claim submitted and approved. Therefore, the total net item allowance per claim will be $1,140. Until the final recall remedy is performed, customers should take the following interim steps: 1. Customers should set their vehicle’s high-voltage battery system to a 90% state of charge limitation using either “Hilltop Reserve” (for 2017-18 MY vehicles) or “Target Charge Level” mode (for 2019-22 MY vehicles). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, customers should visit their dealer to have these adjustments completed. 2. Additionally, we ask that customers charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 KM) of remaining range, where possible. 3. Out of an abundance of caution, customers should continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight. Warranty Administration If you are not a Bolt EV certified dealer or are ineligible to perform the recall repair, the nearest EV certified dealer can be located by: 1. Visiting https://www.chevrolet.com/electric/bolt-euv o Click on the three bars on the upper right-hand of the homepage o Under Support, click on “Find A Dealer” < OR > 2. Contacting the Dealer Business Center, available through Support/Chat in GlobalConnect or by phone (888) 414-6322 Courtesy Transportation Program Dealers seeking to assist Bolt owners, or any other courtesy transportation eligible repair, with rental vehicles should verify with Hertz for available vehicles in support of our rates. Refer to the GM Courtesy Transportation bulletin 07-00-89-037 in GlobalConnect for details.
Until further instructions are received, involved vehicles in dealers’ possession (new or used vehicle inventory, GM Certified Used, courtesy transportation vehicles, dealer shuttle vehicles, etc.) must be held and not delivered to customers, dealer-traded, released to auction, used for demonstration purposes or any other dealer use. All GM Certified Used vehicles currently in the dealers’ inventory within the Certified Pre-Owned Inventory System (CPOIS) have been de-certified.
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6057
URGENT – DISTRIBUTE IMMEDIATELY
Date: February 22, 2022
Subject: N212343881-03 – Safety Recall – REVISION
High Voltage Battery May Melt or Burn
80% SOC Advanced Diagnostic Software available while waiting for HV battery appointment, Customer Letter has been added, and additional vehicles have been moved to ‘Open’ status.
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
This bulletin has been revised in the following areas:
• The 80% SOC Advanced Diagnostic Software is available while the customer is waiting for their High Voltage Battery replacement appointment, if it has not been previously completed in N212343883.
• The customer letter has been added,
Important: If N212343883 (labor code 9105953) has not been previously completed, the 80% SOC Advanced Diagnostic Software is available to the customer while waiting for their high voltage battery replacement appointment. A new unique labor operation, 9106050, has been created for this programming only event. It is a non-closing labor op that will leave the safety recall open until the high voltage battery replacement procedure is completed. Please be sure to refer to the Important note in the Warranty Information section of the revised bulletin.
Please discard all previous copies of bulletin N212343881.
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for final repair in N212343881, they will be closed in N212343880 or N212343883. Remaining VINs in “Incomplete-Remedy Not Available” status under N212343880 and N212343883 will not be eligible for the final repair until GM informs dealers at a future date.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in N212343881 in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the
vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the Advanced Diagnostic Software package, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On February 21, 2022, additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6051
URGENT – DISTRIBUTE IMMEDIATELY
Date: February 15, 2022
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On February 14, 2022, additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6025
URGENT – DISTRIBUTE IMMEDIATELY
Date: January 11, 2022
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On January 10, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
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Eligibility for Servicing Bolt EV and Bolt EUV Recall Updated Date: Oct 25, 2021 17:15 CT Subject: Eligibility for Servicing Bolt EV and Bolt EUV Recall Based on the release of recall (N212343881/N212345941), and until further notice, only fully trained and tooled Chevrolet EV dealers should perform service on EV vehicles. Dealers that are not authorized to complete service on EVs are encouraged to direct customers to Chevy.com to schedule service. Once records indicate that you have met all training and tool requirements, restrictions are removed. Dealers can view any implemented and removed restrictions in Global Warranty Management on your Service Agent Detail Page. Restricted Model Code information is found on the “Other Items Not Allowed” tab (see GCUS-9-12057 below). Keep in mind that Chevrolet EV service requirements must be met on an ongoing basis. Effective Date: 10/21/2021 Additional Information: GCUS-9-12057 – Eligibility for Servicing Chevrolet Electric Models Updated Date: Oct 14, 2021 12:45 ET GCUS-9-11935 – Important Information Regarding the Chevrolet Electric Models Participation Agreement Updated Date: Oct 06, 2021 12:45 ET GCUS-9-11959 – Update – N212343880 / N212345940 – Safety Recall – High Voltage Battery May Melt or Burn Updated Date: Sep 28, 2021 16:30 ET GCUS-3-2335 – N212343881 – Safety Recall – High Voltage Battery May Melt or Burn Updated Date: Oct 07, 2021 15:05 ET GCUS-3-2336 – N212345941 – Safety Recall – High Voltage Battery May Melt or Burn Updated Date: Oct 07, 2021 16:00 ET
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GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6015
URGENT – DISTRIBUTE IMMEDIATELY
Date: December 23, 2021
Subject: N212343881-02 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package (N212343883), customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On December 22, 2021 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS6094
URGENT – DISTRIBUTE IMMEDIATELY
Date: March 22, 2022
Subject: N212343881-03 – Safety Recall
High Voltage Battery May Melt or Burn
Additional Vehicles Have Been Moved to ‘Open’ Status
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement in bulletin N212343881. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for a battery module replacement in N212343881, they will be closed in N212343883. Dealers will be informed as additional VINs become eligible for final repair in bulletin N212343881.
All remaining VINs in N212343883 with an “Incomplete-Remedy Not Available” status are eligible to receive the advanced diagnostic software package.
WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment. Not charging the vehicle before the service appointment and ensuring that the battery’s state of charge is at 90% or less will help speed up the repair procedure.
Until the battery module is replaced (N212343881), OR the vehicle receives the advanced diagnostic software package, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on
(chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
Failure to use the ZFA Multimodule Coordinated sequential programming procedure will result in claim rejection, and may require customer vehicles to return to be reprogrammed.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. On March 21, 2022 additional 2017 – 2019 model year Chevrolet Bolt EV vehicles were moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5980
URGENT – DISTRIBUTE IMMEDIATELY
Date: November 3, 2021
Subject: REVISION – N212343881-01 – Safety Recall
High Voltage Battery May Melt or Burn
Multiple Sections Revised including Vehicle Preparation, Adjusting the State of Charge, and WCAP Clarification
Models: 2017 – 2019 Chevrolet Bolt EV
To: All General Motors Dealers
General Motors is revising Safety Recall N212343881-01 today. This Safety Recall includes select 2017 – 2019 model year Chevrolet Bolt VINs.
This bulletin has been revised in multiple areas, including the “Vehicle Preparation Before Entering the Repair Garage” section, the “Adjusting (Reducing) the SOC” section, and the Working Capital Assistance Program (WCAP) clarification. Please take the time to re-read the entire bulletin thoroughly. Please discard all previous copies of bulletin N212343881.
Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a battery module replacement. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. The Dealer Maxis App via Global Connect can be utilized to download a list of eligible ‘open’ VINs. Dealer Maxis should be queried at a minimum weekly for the most up-to-date information on all open field actions. IVH is the best source for individual VIN inquiries.
As VINs become eligible for repair, they will be closed in N212343880 and moved into N212343881. All other VINs will remain in “Incomplete-Remedy Not Available” status under N212343880 and will not be eligible for the final repair until GM informs dealers at a future date. WCAP is calculated from the “Release Date” on VINs in “Open” Status in IVH and will be adjusted as additional releases occur.
When making customer appointments, please remind the customer to not charge their vehicle 24 hours prior to their scheduled appointment.
Until recall repairs can be completed, customers should take the following interim steps:
1. Set their vehicle to a 90 percent state of charge limitation using Hilltop Reserve mode (for 2017-2018 model years) or Target Charge Level (for 2019 model year) mode. Instructions on how to do this are available on (chevy.com/boltevrecall). If customers are unable to successfully make these changes, or do not feel comfortable making these changes, GM is asking them to visit their Chevrolet EV certified dealer to have these adjustments completed.
2. Charge their vehicle more frequently and avoid depleting their battery below approximately 70 miles (113 km) of remaining range, where possible.
3. Continue to park their vehicles outside immediately after charging and not leave their vehicles charging indoors overnight.
IMPORTANT
To avoid warranty transaction rejections, dealers MUST record the warranty claim code provided on the Warranty Claim Code (WCC) screen. Labor code 9105785 – ZFA – Field Action Multimodule Coordinated Sequence MUST also be used, or the claim will reject.
Question and Answer Document (FAQs)
Attached to this message you will find a document that addresses the twelve most likely questions customers may have regarding this Safety Recall. Please use this information as an aid to confidently answer customer concerns.
Customer Letter Mailing
The customer letter mailing began on October 6, 2021 and will continue as VINs become eligible for the final repair.
Global Warranty Management (GWM)
The Required Field Action section on the IVH screen was first updated on October 7, 2021. Additional 2017 – 2019 model year Chevrolet Bolt EV vehicles have been moved to ‘Open’ status in IVH and are now eligible for a final repair. Please verify a VIN’s involvement in this field action by checking in IVH prior to doing any repairs. IVH is the best source for individual VIN inquiries.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS
**********************************************************************************************************
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86 Associated Documents

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  • CHARGES ALL EVs & PHEVs: Fully compatible with all Electric Vehicles and Plug-in Hybrid Electric Vehicles sold in the United States and Canada. Including: Chevy Bolt, Nissan Leaf, Ford Fusion, BMW i3, Chevy Volt, Toyota Prius, Tesla (with adapter).
  • SUPER FAST CHARGING & EASY INSTALLATION: Charges up to 8x Faster than Standard AC Level 1 EV chargers for an additional estimated 25-35 miles of Range Per Hour. Engineered for ease of Installation with a Standard NEMA 6-50 plug and universal mounting bracket.
  • SAFETY RATED & TESTED: Designed and tested to meet the nationally recognized UL (USA) & cUL (Canada) standards for safety. A must-have for electrical products installed in your home. NEMA 4 rated for Indoor/Outdoor use in all weather.
  • ADJUSTABLE AMPERAGE & MODERN COMPACT DESIGN: Adjust the Max Current Output (32A, 24A, 16A) to Support Multiple Circuit Ratings (40A, 30A, 20A). Install in more locations with a slim, compact & modern design.
  • EVERYTHING YOU NEED INCLUDED: One low price, no need to purchase other items. Includes: charging unit w/ 18 foot cable, NEMA 6-50 plug, universal mounting bracket, plug holster & user manual.
Bestseller No. 2
ChargePoint Home Flex Electric Vehicle (EV) Charger upto 50 Amp, 240V, Level 2 WiFi Enabled EVSE, UL Listed, Energy Star, NEMA 6-50 Plug or Hardwired, Indoor/Outdoor, 23-Foot Cable
  • Level 2, 240 volt electric vehicle (EV) charging station charges any EV up to 9X faster than a normal wall outlet, with flexible amperage settings up to 50 amps (16/24/32/40/48/50 Amp) and plug-in or hardwired installation. Use the ChargePoint app to pick the right amperage for your home after installation.
  • Works with all electric cars, tested on leading EV models: Chevrolet Volt and Bolt EV, Hyundai Kona and Ioniq, Kia NIRO, Nissan LEAF, Tesla models, Toyota Prius Prime, BMW i3, Honda Clarity, Chrysler Pacifica, Jaguar I-PACE, and many more
  • Charge faster and smarter with the ChargePoint app. Set a schedule to only charge when electricity is cheapest, set reminders so you never forget to plug in, use Alexa voice control, and see all your ChargePoint charging data in one place
  • Safe and reliable, with a 3-year backed by 24/7 customer support from a company dedicated to EV charging for 10+ years. UL listed for electrical safety, ENERGY STAR certified for efficiency.
  • Easy for any electrician to install indoors or out. Plug-in installation with NEMA 6-50 or 14-50 outlet (6-50 currently selected) requires circuits rated 40A or 50A. For other circuit ratings, including 60A-80A for 48A-50A charging, the plug is easily removed for hardwired installation. Select the amperage that works best for you and your home, helping to avoid electrical upgrades.
Bestseller No. 3
MEGEAR Skysword Level 1-2 EV Charger, 100-240V 16A 25FT Portable EVSE, NEMA 6-20 Plug with NEMA 5-15 Adapter Electric Vehicle Charging Station
  • High-Speed Charging: When compared to the stock 8A level 1 charger, MEGEAR Skysword EV Charger is 3 times as fast with NEMA 6-20, leaving you with more time to get back on the road in your EV.
  • Reliability to the Fullest: Our smart-chip detection system in MEGEAR Skysword electric vehicle charger can detect all aspects of the charging progress, including overheating, current overflow, power surge, low voltage, power overload, leakage to ensure safety and protection.
  • Compatible with all EVs: MEGEAR Skysword ev charging station is compatible to all SAE J1772 standard electric vehicles and Tesla models (via SAE J1772 Charging Adapter).
  • LED Indicator: Indicator on the back of MEGEAR Skysword portable EV Charger displays charging progress and errors.
  • Warranty Information: All products come with a 2-Year Limited Warranty and Life-time technical support. If the product is damaged or lost the accessories during transportation, please contact us in time. We will resend replacement or accessories for you immediately.
Bestseller No. 4
PRIMECOM Level 2 Electric Vehicle (EV) Charger (220V / 240Volt, 16Amp) Portable EVSE Smart Electric Car Charger, 30', 40', and 50 Feet Lengths (NEMA 10-30P, 50 Feet)
  • UNIVERSAL COMPATIBILITY Works with all brand EV and PHEVs : but for Toyota Prius & RAV4 please call us first for special non standard J1772 plugs. Up to 4 times FASTER CHARGING speed PRIMECOM Level 2 chargers function at 16 Amps working within an automatic range of 100V-240V works with all brand EVs & PHEVs & Plug-in Hybrids. This 16 Amp model charges at 3.84kw/hour giving upto 15 miles of range per hour! If you need 40/ 50-feet length 32/40Amp chargers
  • INTELLIGENT CHIP -PRIMECOMTECH designs its own SMART chargers electronic circuitry-intelligent Chip & software here in the USA, unlike other chargers which dump all the current at once. PRIMECOMTECH EV Chargers communicate with your EV via the data connection port to gather 6 different types of data such as, ambient and battery temperature, EVs current battery level, Battery Capacity, etc. to automatically adjust the voltage to get the longer / most life expectancy from your battery.
  • SAFE AND SECURE - Primecom Level 2 Chargers have passed multi point rigorous tests to ensure quality and safety measures. T V German Equipment and Product Safety Certification, CE️ certifications, UL️ Listed Cable Certifications, along with 12 other built in safety features such as, lightning-proof, leakage protection, overvoltage, overheat, overcurrent protection, UL94V-0 rating flame resistance, IP65 rating waterproof and are safe to use outdoors for snow, rain, dust...
Bestseller No. 5
Schumacher SEV1600HW Level 2 50A 240V Hardwired Electric Vehicle (EV) Wall Charger, Wi-Fi/Bluetooth Connected, 25-Foot Charging Cable, Indoor/Outdoor, 9X Faster Charging
  • MAXIMUM POWER: The Schumacher SEV1600HW employs 240V Level 2 charging with up to 50A of power
  • 9X FASTER CHARGING: Enjoy the convenience of faster Level 2 EV charging at home with charging speeds that are up to nine times faster than standard wall outlet
  • CONFIGURABLE CURRENT: The Schumacher SEV1600HW has configurable current, from 16A to 50A, that can be adjusted during installation to your home’s power system
  • BUILT-IN CONVENIENCE: The interchangeable dock lets you store the charging gun on either side of the unit to suit your needs and cord management is simple with the included cable cradle
  • EXTRA-LONG CHARGING CABLE: An extended 25-foot charging cable gives you flexibility, allowing you to easily reach multiple garage bays or your home’s driveway; It makes charging multiple EVs easy
Bestseller No. 6
Lectron NEMA 10-30 Level 2 EV Charger - 240V / 16 Amp - with 21 ft Extension Cord - Compatible with J1772 EVs
  • FAST CHARGING – Designed to make EV charging quick and effortless. Utilizing the standard J1772 charging protocol, this charging cable is compatible with all electric cars and plug-in hybrid. Compact and durable, it is the perfect charging cable for home use and with a 21ft cable that’s long enough for most driveways or garages
  • LEVEL 2 CHARGER – Our Level 2 charging cable will offer you 3x the charging speed in comparison to your car’s original charger. Boosting 240V and up to 16A, it provides a rapid charging rate of 3.86kw/hour, which equates to approximately 11 miles per hour of charge
  • HIGH QUALITY – The charging station is rugged and robust, equipped with overvoltage, overheat and overcurrent protection. The indicating light on the charging station helps to show the various stages of charging and to warn of possible errors
  • TECHNICAL SPECS – Input Power: 240V AC, Voltage Range 185V AC to 264V AC, Frequency: 60Hz, Maximum Current: 16A, Cable Length: 21ft (6.4m), Plug: NEMA 10-30, Weight: 3.3kg (7.3lbs), Operating Temp: -30C (-22F) to 50C (+122F)
  • LECTRON 1 YEAR WARRANTY – If any of our products fail to meet your expectations, please get in touch with us and we will try to resolve the issue. If we can't resolve the problem to your satisfaction, you will get a full refund or replacement - no questions asked
Bestseller No. 7
VEVOR Level 1+2 EV Charger, 16 Amp 110-240V, Portable Electric Vehicle Charger with 25 ft Charging Cable NEMA 6-20 Plug NEMA 5-15 Adapter, Plug-in Home EV Charging Station for SAE J1772 Electric Cars
  • Faster Charging Speed: VEVOR 16A level 1+2 portable EV charger is designed to make EV charging quick and effortless. This EV portable charger with NEMA 6-20 plug could charge your car 4x faster than other 8A level 1 EV chargers you have used before. The actual charging speed depends on the settings of your electric vehicle.
  • Excellent Protection: The portable level 1+2 charger features an intelligent chip to provide lightning / leakage / grounding / over voltage / under voltage / over charge / over current / overheat protection. With CE certification, IP65 control box and an IP54 EV connector to secure your car charging.
  • LED Indicator Lights: The LED indicator lights on the control box show four different status: read to connect to vehicle, charging, full charged, see troubleshooting. Help you identify the EV charger's working condition and let you know the relevant charging information. It alerts you if a fault is discovered, allowing you to manage the problem immediately.
  • Portable & Convenient: Provide a fireproof NEMA 5-15P to 6-20R adapter, 12 gauge SWG indoor/outdoor heavy-duty cord. The 22-7/16 inch length is 100% longer than other adapters, making it stand out from the rest. There is also a portable bag, both are fine products.
  • Universal Compatibility: The EV charger is compatible with most electric vehicles and plug-in hybrid vehicles that comply with the J1772 standard. Perfect for users who own more than one electric vehicle or buildings with docks for EV charging. When traveling or visiting relatives and friends, you don't have to worry about charging again.
Bestseller No. 8
Electrify America Electric Vehicle (EV) Charger, Level 2, WiFi Enabled, 16 to 40 Amp, 240V, UL Listed, Energy Star, Indoor / Outdoor, 24-Foot Cable, NEMA Plug, Remote Access, App Control
  • LEVEL 2 EV CHARGER: Electrify Home's Level 2 EV Charger, HomeStation provides up to 9.6 kW of available power at 40 Amps for quickly charging capable electric vehicles (EV). Flexible charger amperage between 40A, 32A, and 16A.Tested and Certified to meet UL standards for safety (UL 2594, UL 2231-1&2). SAE-J1772 compliant for all current US electric vehicles. ENERGY STAR certified.
  • SMART CHARGER: HomeStation is WiFi ready with app control and features the Electrify America app for managing your charger remotely at home, all while connecting to the largest public charging network in the country. Smart charging features include remote access control, remote start/stop, notifications/reminders, scheduled charging, and OTA updates.
  • FLEXIBLE INSTALLATION OPTIONS: For easy installation, HomeStation Level 2 home charger comes with a standard NEMA 14-50 supply power plug, compatible with the 240 volt outlets commonly found in households. Any existing 240-volt outlet should be inspected by a certified and qualified electrician. Weatherproof enclosure allows for indoor or outdoor installation. The unit can also be hardwired by a licensed electrician.
  • 24 HOUR CUSTOMER SUPPORT: Including 3-year limited warranty (Parts only).
  • COMPATIBILITY: Electrify America Level 2 Electric Vehicle Charger is compatible with all current US electric vehicles, including: Tesla Model S, Volkswagen ID.4, Ford Mach-E, Chevrolet Bolt EV, Audi e-tron, KIA Soul EV, BMW i3, VW e-Golf, Jaguar I-PACE.
SaleBestseller No. 9
Duosida Level 1+2 EV Charger(120-240V,16A,25ft) Portable EVSE Home Electric Vehicle Charging Station Universal
  • 3x Faster Charging Speeds : The Duosida Level 2 Car Charger charges your car up to 3x faster than your standard Level 1 charger . Comes with instruction booklet.
  • Universal Vehicle Compatibility : Compatible with All EV Cars
  • 25 ft. long charge cord with 16 amp , 220v NEMA 6-20p plug.
  • Free 110v standard outlet adapter for level 1 charging.
  • The charger comes with a 2-year warranty , so please feel free to contact us.
Bestseller No. 10
Autel MaxiCharger Home Electric Vehicle (EV) Charger, up to 50 Amp, 240V, Level 2 WiFi and Bluetooth Enabled EVSE, Hardwired, Indoor/Outdoor, 25-Foot Cable with Separate Holster, Dark Gray
  • Engineered by Autel, the industry-leader in automotive diagnostic tools since 2004, the MaxiCharger Home is a Level 2, 240 Volt electric vehicle (EV) charging station that can charge any EV or plug-in hybrid up to 9X faster than a Level 1 regular outlet charger.
  • The advanced Autel Charge mobile app allows you to track, manage, schedule, and optimize smart EV charging anytime to take advantage of off-peak electricity rates. Adjustable power output up to 50 Amps allows you to choose what works best for your home and lifestyle, helping to avoid costly electrical upgrades.
  • A durable 25-foot cable, sturdy construction, and high-grade materials provide maximum weather resistance. A NEMA 4 protection rating provids safe and reliable indoor and outdoor usage in any climate.
  • Wi-Fi, Bluetooth, and Ethernet connectivity options ensure automatic OTA (over-the-air) firmware updates and seamless connectivity and communication with your mobile device. The optional start and stop RFID card functionality can prevent unauthorized use.
  • A 3-year warranty, 24/7 support from the best-in-class charging stations customer service, and automatic updates will deliver safe and secure electric vehicle charging for years to come.

Last update on 2023-01-26 / Affiliate links / Images from Amazon Product Advertising API

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