Chevrolet Bolt EV Battery and High Voltage Components Overview

Battery and Charging System Specs and Info

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

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