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Chevrolet Bolt EV Battery and High Voltage Components Overview

Chevrolet Bolt Battery Coolant System Breakdown


Bolt EV High Voltage Components Video

John D. Kelly at Weber University does a video of the Chevy Bolt’s high voltage components.

Video timeline:
Video introduction at 0:12
See the under hood view with everything removed at 1:04
See the traction motor Drive Unit (DU) at 3:56
See the under hood cross-car beam at 7:28
See the Single Power Inverter Module (SPIM) at 8:32
See the High Power Distribution Module (HPDM) without fast charge at 10:10
See the High Power Distribution Module (HPDM) with fast charge at 11:29
See the on-Board Charger Module (OBCM) at 13:35
See the Accessory Power Module (APM) at 15:26
See the Air Conditioning Compressor Module (ACCM) at 17:39
See the High Voltage Battery Coolant Heater at 19:20
See the 3-Phase cable connections at 20:27
See the HPDM to SPIM harness connection at 22:25
See the HV battery to HPDM harness connections at 23:08
See the HPDM to APM and OBCM connections at 25:33
See the DC Fast Charge receptacle to HPDM connection at 26:57

Chevrolet Bolt Battery Pack Removal


Video introduction at 0:10
High voltage disabling procedure at 0:26
Key fob removal at 0:39
12V battery negative cable disconnection at 0:59
12V system description at 1:25
High voltage service disconnect lever removal at 2:29
Removal of high voltage connector at 6:45
Verification of multimeter proper operation at 5:55
Verification of no voltage at inverter at 7:15
High voltage battery location at 9:20
Battery connections at 9:30
*Verification of no voltage at the AC charger connection 10:18
Verification of no voltage at the DC battery to inverter connection at 11:48
Disconnection of low voltage connections at 13:30
Draining the battery cooling system at 13:57
MUST SEE – Do you have a first or second design battery? at 17:00
MUST SEE – Better view of battery coolant connections 18:40
Disconnecting the battery bonding straps at 19:15
Finding the battery Center of Gravity at 19:48
Positioning the battery removal table at 20:23
Battery weight 1000 lbs (453.59 kg) at 20:25
Removing the battery to body bolts at 20:50
MUST SEE – Partial lowering of the battery at 21:58
Leveling the battery lift at 22:32
MUST SEE – My apprehension regarding lowering the battery at 23:17
MUST SEE – Lowering the Bolt battery at 24:10
Battery external review at 25:12
MUST SEE – High Voltage Service Disconnect connector and lever at 28:19
Under car views at 29:10
High voltage battery coolant heater at 30:53
High voltage Air Conditioning compressor at 30:58
Traction motor and differential at 31:04
Leaking steering rack at 31:14
Video review at 32:11

Chevrolet Bolt Battery Pack Disassembly

Video introduction at 0:13
Corrections to battery removal video at 0:43
Charger connections at battery at 1:00
Undercar aerodynamic cover at 3:19
Removal of battery upper cover at 5:19
Battery cover seal removal at 7:24
Battery inside views at 8:00
Removal of large 2-wire connector at 12:27
Removal of Battery Disconnect Relay Center Cover at 13:29
Removal of charger connector at 13:39
Removal of Battery Disconnect Relay Center at 14:20
Removal of coolant from the battery at 18:50
Removal of internal coolant hoses at 27:40
Preparation for removal of battery section 5 at 29:38
Connections at the Battery Energy Control Module (BECM) at 30:20
Removal of internal wire harnesses at 34:04
Removal of Service Disconnect lever connector at 38:44
Removal of BECM at 39:33
Removal of battery bus bars at 40:00
Removal of battery section 5 cover at 43:16
MUST SEE: True battery kWh rating at 44:25
Stabilization of battery before removal of sections at 46:42
MUST SEE: Removal of battery section 5 at 50:42
Battery thermal conduction mats at 53:00
Closer look at battery section 5 at 53:48
Removal of battery section 1 at 57:15
Removal of battery section 2 at 1:06:35
Removal of battery section 5 cooling plate at 1:08:30
Spilling coolant on myself at 1:11:35
MUST SEE: Warning about battery section 2 at 1:14:24
Removal of battery section 3 at 1:14:53
Removal of battery section 4 at 1:15:20
MUST SEE: View underneath battery section 4 at 1:21:13
Removal of 4 cross-braces at 1:21:57
Removal of large cooling plate at 1:26:10
MUST SEE: View of underneath of large coolant plate at 1:30:04
Removal of insulation pads at 1:30:46
Removal of final connector bracket at 1:33:08
Video review at 1:33:55


Re-Assembly of Chevrolet Bolt battery pack

Video Timeline:

Video introduction at 0:11
Battery tray at 0:57
MUST SEE: Battery tray weight at 1:38
Battery tray inspection plug at 2:35
Battery center of gravity mark at 3:20
The red shop stools at 4:20
The cooling plates at 5:39
The bus bars, BECM, low and high voltage harnesses at 6:43
Battery disconnect relay assembly at 7:23
Battery sections at 8:20
Reassembly procedures
Insulation pads at 9:35
Lower cooling plate at 10:30
Thermal pads at 11:18
Battery tubes at 19:48
X3 connector housing at 20:47
Cooling manifolds at 21:16
Battery Section Details
Safety zone at 22:38
Don’t freak out! 40 Volts will not hurt you at 23:00
Battery section 1 at 24:00
Battery module 1 with cell groups 1-10 at 25:27
Battery module 10 with cell groups 87-96 at 26:35
How the battery modules are connected together at 26:56
Battery section 5, module 5, details at 28:57
What is a cell group? at 31:36
How the Battery Energy Control Module (BECM) monitors cell voltages at 32:24
Special tool to measure cell voltages at 32:42
MUST SEE: Battery section 5, module 5, side cover removal at 33:37
MUST SEE: Closeup views of a cell group connections at 34:45
Cell group direct voltage measurement at 35:21
How cell groups are electrically connected at 35:40
Cell group voltage measurement with special tool at 36:56
MUST SEE: Can you take the battery module further apart? at 38:50
Installing battery section 1 at 41:24
Installing battery section 2 at 44:23
Installing battery section 3 at 45:25
Installing battery section 4 at 46:34
Attaching the battery sections to the battery tray 48:06
Battery section 4 voltage cell sensing harnesses at 50:23
Battery section 5 lower support brackets at 51:37
Battery section 5 insulation pad at 53:20
Battery section 5 cooling plate and hose clamps at 53:36
Battery section 5 at 54:54
Battery section 5 upper support brackets at 57:53
Time for Personal Protective Equipment (PPE) at 59:30
MUST SEE: Installation of high voltage bus bars at 1:00:17
Overall battery negative and positive terminals at 1:03:36
Low voltage wiring harness and temperature sensors at 1:04:57
Interlock circuit at the service disconnect lever connector at 1:07:00
High voltage cell voltage sensing harnesses at 1:08:18
MUST SEE: BECM details at 1:09:34
MUST SEE: BECM installation at 1:13:05
MUST SEE: Battery relay assembly components and operation at 1:20:01
MUST SEE: Battery relay assembly operation at 1:33:24
Cooling system leak check at 1:38:26
Installation of battery relay assembly at 1:40:52
X3 Connector installation at 1:44:23
X4 Charge connector installation at 1:44:57
MUST SEE: Battery system overview at 1:47:12


Updated on December 17, 2018

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