Safety Recall N212345941 High Voltage Battery May Melt or Burn – 2020-2022 Chevrolet Bolt EV & 2022 Chevrolet Bolt EUV

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Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Copyright 2022 General Motors. All Rights Reserved. Page 1 of 46 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 N212345941. 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 N212345940 on August 20, 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 N212345940. N212345940 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 N212345940 into the population of this bulletin N212345941 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 N212345942. Table of Contents Content Page Number Vehicle Preparation Before Entering the Repair Garage 2 Adjusting (Reducing) the SOC 2 Storage Guidelines 3 Parts Ordering Information 3-4 Parts Retention and Return 4-5 Warranty Information 6-7 Tool Specifications 7 Personal Protective Equipment 8 High Voltage Battery Replacement Service Procedure 8-9 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 2 of 46 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 32-39 Final Shipping Preparation 39-46 Make Model Model Year RPO Description From To Chevrolet Bolt EV 2020 2022 Chevrolet Bolt EUV 2022 2022 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 2020-2022 model year Chevrolet Bolt EV, and 2022 model year Chevrolet Bolt EUV 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 defective battery modules. 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. Adjusting (Reducing) the SOC 5905973 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 3 of 46 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 * 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. Storage Guidelines for Containerized High Voltage Batteries • Store the High Voltage Battery and shipping crate flat. • 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 4 of 46 Parts Ordering Information For Markets other than US and Canada, refer to Field Action bulletin N212345942. 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 N212345941 High Voltage Battery May Melt or Burn Page 5 of 46 Parts Retention and Return For Markets other than US and Canada, Refer to Field Action bulletin N212345942. 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: [email protected]. 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 N212345941 High Voltage Battery May Melt or Burn Page 6 of 46 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 N212345942. Labor Operation Description Labor Time Trans. Type Net Item 9105933* Drive Motor Battery Replacement and Shipping Preparation (Includes ZFA – Field Action Multimodule Coordinated Sequence Programming, Capacity Learn, EV Range Reset) (Using Forklift) ADD: Using Engine Hoist ADD: High Voltage Battery (Reduce SOC) 4.5 0.5 0.2 ZFAT ** 9106051 80 Percent SOC Adv Diag Software – waiting for HV Battery Appointment (use only if N212345940 not previously completed) ADD: SOC Depletion to 80% 1.0 0.3 *** 9106000 Floor Plan Reimbursement – NEW INVENTORY ONLY N/A **** 9106001 Working Capital Assistance Program Reimbursement – USED INVENTORY ONLY N/A ***** Note: * To avoid having to “H” route the floor plan / 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 N212345940 (labor code 9105957) 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 N212345940. A new unique labor operation, 9106051, 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 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 7 of 46 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. Floor Plan Reimbursement – NEW INVENTORY ONLY **** USA & Canada Only – For vehicles eligible for floor plan reimbursement, the amount should be submitted in Net Item/Miscellaneous. This amount should represent the product of the vehicle’s average daily interest rate (see table below) multiplied by the actual number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop delivery message August 20, 2021 to the date the VIN was placed in “open” status in IVH. (Maximum Number of days for Floor Plan is calculated from the “Release Date” on VINs in “Open” Status in IVH, and will be adjusted as additional releases occur.) Vehicle Floor Plan Reimbursement Amount USA Canada 2022 Chevrolet Bolt EV $4.14 $5.25 2022 Chevrolet Bolt EUV $5.18 $5.88 2021 Chevrolet Bolt EV $4.75 $6.43 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, 9800078, provided in the dealer message sent on August 20, 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 August 20, 2021 to the date the VIN was placed in “open” status in IVH. (Maximum Number of days for 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 2021 Chevrolet Bolt EV $12.56 $16.38 2020 Chevrolet Bolt EV $9.98 $13.52 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 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 8 of 46 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. 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 inches (122 cm) (minimum). ▪ Two (2) 4x4s length 60 inches (152 cm) (minimum). ▪ Two (2) 2x4s length 60 inches (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: Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 9 of 46 ▪ 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. • 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 10 of 46 • Identify how to test for the presence of high voltage. • Identify condition under which high voltage is always present and Personal Protection Equipment (PPE) and proper procedures must be followed. • Before working on any high voltage system, be sure to wear the following Personal Protection Equipment: – Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors. – Certified and up-to-date Class “0” Insulation gloves rated at 1000V with leather protectors. • Visually and functionally inspect the gloves before use. • Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not. Failure to follow the procedures may result in serious injury or death. 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 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 11 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 12 of 46 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). Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 13 of 46 4587655 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 14 of 46 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. 5903435 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 15 of 46 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 16 of 46 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). 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 SERVICE high voltage battery in the crate and dispose of screws appropriately (2 on each side of the battery). Lag screws will NOT be used when the removed high voltage battery is returned in the crate-DO NOT REUSE LAG SCREWS. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 17 of 46 4587656 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 inches (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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 18 of 46 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 1. 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. 2. With the drive motor battery (2) on the GE-52200 Lifting Table (1), slowly raise the lifting table. 3. Release the straps. 4. Continue to raise the battery into position for installation. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 19 of 46 4834282 Caution: Refer to Fastener Caution in SI. 5. Snugly tighten the outside mounting fasteners (1). 6. Lower the lifting table. 7. Tighten the fasteners (1) to 56 Nm (41 lb. ft). 4834281 8. Connect the body wiring harness connectors (3) to the drive motor (high voltage) battery. 9. Connect the X3 high voltage connector (2) to the drive motor (high voltage) battery. 10. Connect the X4 high voltage connector (1) to the drive motor (high voltage) battery. 4505400 11. Install the battery negative cable (2) to the high voltage battery and body structure. Refer to Battery Negative Cable Replacement in SI. 12. Untie the straps that are installed to avoid the vehicle potentially falling off from the lift/hoist. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 20 of 46 13. 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. 13.1. Disconnect the 12v battery after completing the coolant filling procedure. 14. Check the cooling system for leaks. Refer to Hybrid Cooling System Leak Test in SI. 15. Install the front compartment air deflector. Refer to Front Compartment Air Deflector Replacement in SI. 16. Enable the high voltage system. Refer to High Voltage Enabling in SI. 17. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 21 of 46 5743643 Important: If the vehicle VIN DOES NOT match, the message below will be shown. 5877000 5644477 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 22 of 46 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. 5644478 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 23 of 46 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. 9105933 – 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 24 of 46 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 Range Reset Perform the Hybrid/EV range reset using the steps below. 1. The Hybrid/EV range reset 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. 5882921 1.3. Select Hybrid Powertrain Control Module 2 Configuration/Reset Functions. Select the Reset Functions. 5882921 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 25 of 46 5882922 1.4. Using GDS2, reset the EV Range by selecting “EV Range Reset”. Return Vehicle to 100% Charging For 2020-2022 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 26 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 27 of 46 • 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 N212345942. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 28 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 29 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 30 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 31 of 46 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. 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 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 32 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 33 of 46 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. 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) 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 34 of 46 6. Attach lift kit straps to eyebolts on REMOVED high voltage battery on Lift Table. 4587658 • 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. 5903432 5903803 8. Set-up cribbing under Hoist & high voltage battery to place REMOVED high voltage battery on from the Lifting Table. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 35 of 46 • 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 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 36 of 46 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). 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 37 of 46 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). Lag screws will NOT be used when the removed high voltage battery is returned in the crate-DO NOT REUSE LAG SCREWS. 4587658 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). 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 38 of 46 4587656 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 39 of 46 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: 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 N212345942. 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 Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 40 of 46 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. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 41 of 46 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. 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. 4587658 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 42 of 46 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 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 43 of 46 5903454 16. Open a 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 20. 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 17. 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 18. 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 44 of 46 5903458 19. 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 20. 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 21. Reverse the (2), Class 9 panels to read Damaged / Defective (one on each side of the crate). 22. Open the three (3) release clips and reverse the panel to show UN3480 – DAMAGE / DEFECTIVE side. 23. Close the three (3) clips to secure the panel in place. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 45 of 46 5903463 24. 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). 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. Product Safety Recall N212345941 High Voltage Battery May Melt or Burn Page 46 of 46 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. 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 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. Export – Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. 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 October 2021 This notice applies to your 2020-2022 model year Chevrolet Bolt EV or Bolt EUV vehicle. The applicable Vehicle Identification Number (VIN) can be found on the address label of the envelope. This notice applies to your vehicle, VIN: . Dear GM 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 2020-2022 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 N212345941. • 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 defective 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 defective 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 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 N212345941

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GLOBAL SAFETY FIELD INVESTIGATIONS DCS5956 URGENT – DISTRIBUTE IMMEDIATELY Date: October 07, 2021 Subject: N212345941 – Safety Recall High Voltage Battery May Melt or Burn Models: 2020-22MY Chevrolet Bolt EV and Bolt EUV To: All General Motors Dealers General Motors is releasing Safety Recall N212345941 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 N212345940 and moved into N212345941. 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 N212345940 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 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, customers should 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 DCS6063 URGENT – DISTRIBUTE IMMEDIATELY Date: February 28, 2022 Subject: N212345941-03 – Safety Recall – REVISION High Voltage Battery May Melt or Burn 80% SOC Advanced Diagnostic Software available while waiting for HV battery appointment and additional vehicles have been moved to ‘Open’ status. Models: 2020 – 2022 Chevrolet Bolt EV and Bolt EUV 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 N212345940. Important: If N212345940 (labor code 9105957) 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, 9106051, 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 N212345941. Additional 2020 – 2022 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 N212345941, they will be closed in N212345940. Remaining VINs in “Incomplete-Remedy Not Available” status under N212345940 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 N212345941 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 (N212345941), 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 Target Charge Level (for 2020 and newer model years) 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 Limited customer letter mailing will begin on February 28, 2022 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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GLOBAL SAFETY FIELD INVESTIGATIONS DCS6011 URGENT – DISTRIBUTE IMMEDIATELY Date: December 21, 2021 Subject: REVISION – N212345940-01 – Safety Recall High Voltage Battery May Melt or Burn Revised Service Procedure involving Advanced Diagnostics Software Update for 2020-2022 Model Year Vehicles Models: 2020 – 2022 Chevrolet Bolt EV 2022 Chevrolet Bolt EUV To: All General Motors Dealers This bulletin has been revised to replace the service procedure with the Advanced Diagnostic Software using the sequential ZFA – Field Action Multimodule Coordinated Sequence programming. Please discard all previous copies of bulletin N212345940. General Motors has developed an advanced diagnostic software package in N212345940-01 that will remove parking and charging limitations on 2020-2022 model year Bolt EV or 2022 model year Bolt EUV 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 N212345941. 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 113 km (70 miles) 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 N212345940-01 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 immediately review with their District Service Manager. Question and Answer Document (FAQs) Attached to this message you will find a document that addresses the 12 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 will begin on December 21, 2021. Global Warranty Management (GWM) The Required Field Action section on the IVH screen was first updated on August 20, 2021. The VINs will have a status of “Incomplete-Remedy Not Available” even after the completion of the service procedure. Dealers should submit warranty claims for affected vehicles after the procedure in bulletin N212345940-01 is successfully completed. END OF MESSAGE GLOBAL SAFETY FIELD INVESTIGATIONS

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GLOBAL SAFETY FIELD INVESTIGATIONS DCS6001 URGENT – DISTRIBUTE IMMEDIATELY Date: December 08, 2021 Subject: REVISION – N212345941-02 – 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. Models: 2020 – 2022 Chevrolet Bolt EV 2022 Chevrolet Bolt EUV 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 N212345941. Please verify a VIN’s involvement in this field action by checking in IVH prior to performing 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 this repair, they will be closed in N212345940 and moved into N212345941. All other VINs will remain in “Incomplete-Remedy Not Available” status under N212345940 and will not be eligible for this repair until GM informs dealers. 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, 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 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, customers should 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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GLOBAL SAFETY FIELD INVESTIGATIONS DCS5981 URGENT – DISTRIBUTE IMMEDIATELY Date: November 3, 2021 Subject: REVISION – N212345941-01 – Safety Recall High Voltage Battery May Melt or Burn Multiple Sections Revised including Vehicle Preparation, Adjusting the State of Charge, and WCAP Clarification Models: 2020 – 2022 Chevrolet Bolt EV 2022 Chevrolet Bolt EUV To: All General Motors Dealers General Motors is revising Safety Recall N212345941-01 today. This Safety Recall includes select 2020 – 2022 model year Chevrolet Bolt EV & 2022 Chevrolet Bolt EUV 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 N212345941. 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 additional VINs become eligible for repair, they will be closed in N212345940 and moved into N212345941. All other VINs will remain in “Incomplete-Remedy Not Available” status under N212345940 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 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, customers should 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 9105933 – 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. 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 DCS6122 URGENT – DISTRIBUTE IMMEDIATELY Date: April 13, 2022 Subject: N212345941-04 – Safety Recall – REVISION High Voltage Battery May Melt or Burn High Voltage Battery Part Numbers have been removed from the Parts Table Models: 2020 – 2022 Chevrolet Bolt EV and Bolt EUV 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 N212345941. As VINs become eligible for final repair in N212345941, they will be closed in N212345940. Remaining VINs in “Incomplete-Remedy Not Available” status under N212345940 will not be eligible for the final repair until GM informs dealers at a future date. 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 (N212345941), 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 Target Charge Level (for 2020 and newer model years) 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 Limited customer letter mailing began on February 28, 2022 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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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 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

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