PIC5520P

File in Section:
Service Bulletin
Bulletin No.:
Date:
PIC5520P
September, 2015
PRELIMINARY INFORMATION
Subject:
BAS+ (HYBRID) eAssist Drive Motor Generator Battery Module (Powerpack) or Drive
Motor Generator Battery Section Exchange Process And Order Instructions
Models:
2012 - 2015 Buick Lacrosse, Regal
2013 - 2014 Chevrolet Malibu ECO
2014 - Chevrolet Impala
All equipped with eAssist (RPO HP6)
This PI was superseded to update Administrative Details and to remove part numbers.
Please discard PIC5520N.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Condition/Concern
As part of our ongoing quality improvement process, effective June 13, 2011 the Drive Motor Generator Battery
Module and Drive Motor Generator Battery Sections for the 2012 - 2015 Buick LaCrosse, Buick Regal, 2013 - 2014
Chevrolet Malibu ECO and 2014 Chevrolet Impala with eAssist are being placed on restriction through the General
Motors Technical Assistance Center (TAC).
This P/I will explain the Exchange Program for all models listed above. It is expected that this exchange program will
remain in effect for a minimum of 12 months.
Product teams continually seek valuable information for engineering improvements. This exchange program is also
designed to gain important feedback on the Drive Motor Generator Control and Battery Module Assembly or Battery
Sections regarding service diagnostics, repair procedures, and accelerated root cause analysis for continuous
improvements.
After obtaining a case number and authorization through TAC, the TAC Consultant will call the dealer’s local
Electronic Service Center (ESC) to order the Drive Motor Generator Battery Module (Powerpack) or Drive Motor
Generator Battery Sections 1 and 2.
Recommendation/Instructions
Important: DO NOT ATTEMPT TO REPROGRAM SOFTWARE OR CLEAR ANY DTCs PRIOR TO CAPTURING
DATA AND CALLING TAC
Prior to calling TAC, please, completely follow diagnosis guidelines and obtain all required information as provided in
the Recommendation/Instructions portion of this PI. This will minimize the time spent on the telephone and prevent
the need for multiple calls to TAC. Guidelines for honoring this exchange program are being strictly enforced. To
obtain a replacement Powerpack or Battery Sections, the servicing eAssist technician must provide TAC with a
detailed customer complaint, conditions, diagnostic trouble codes (DTCs), Freeze Frame/Failure Records and other
useful information as outlined below
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 will perform the following tasks:
• Identify how to disable high voltage.
• Identify how to test for the presence of high voltage.
• Identify condition under which high voltage is always present and personal protection equipment (PPE) and
proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
• Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or
outdoors.
• Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
– Visually and functionally inspect the gloves before use.
– 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.
Danger: Ensure all High Voltage safety procedures are followed. Failure to follow the procedures exactly as
written may result in serious injury or death. Have an eAssist trained hybrid technician follow the diagnostic
procedures below prior to contacting TAC.
1. If DTCs are present and procedure gives direction to remove internal components; STOP, record Freeze Frame/
Failure Record stored data, view vehicle wide DTCs and Module ID information with GDS2. Any data reviewed
will be included in your GDS2 Session Log. If possible, test drive vehicle with GDS2 and MDI connected to
capture data from the Hybrid Powertrain Control Module (HPCM) 14V Power Module and Battery Energy
Control Module (BECM) Voltage menus, including any other menus as needed, when condition occurs. See the
latest version of PIP4902 for instructions on GDS2 data collection and how to email the log to TAC. TAC may
request that you email the Session Log to them.
2. If DTCs are not present, refer to Hybrid/EV Controls - Symptoms - Hybrid Controls in G.S.I.
3. If any diagnostic procedure gives direction to remove internal components, stop and call TAC, internal
components should not be removed at this time.
4. Upon review of the diagnosis, TAC will establish a case reference number and will call the dealer’s local ESC to
order the Powerpack or Battery Sections for your dealership if necessary.
5. The dealership should provide any important shipping instructions and the TAC Consultant will confirm the
shipping information with the dealership that is requesting the order.
6. Disable the high voltage system. Refer to G.S.I. for the High Voltage Disabling Procedure.
7. Remove the Powerpack or Battery Sections as required. Refer to Generator Control and Battery Module
Replacement and Shipping Preparation.
8. Prior to contacting TAC, make sure you know:
– The parts department fax number
– The Powerpack serial number (Battery Identification Number)
9. The Battery Identification Number (BIN) tag is located on the side of the assembly cover. Locate the tag and
record the 16 digit Battery Identification Number. The BIN number begins with digits "20T" (See Photo Below). If
the Generator Control and Battery Module is not out of the vehicle yet, you can find the assembly ID number by
installing the MDI and using GDS2. Access the Battery Energy Control Module menu and look under the ID
Information section for the sixteen digit number. It will be listed under the parameter: Hybrid Battery Pack
Identification Number. You will need to record the serial number and supply it to TAC when requesting a
Powerpack or Battery Sections.
2688041
10. Once received, install the Drive Motor Generator Control and Battery Module Assembly.
11. Refer to G.S.I. for Programming and Setup Procedures under the Control Module Reference Table for Modules
K59/107A GCM (HPCM/DMCM) and K16 BECM.
12. Charge pack to at least 30% SOC by driving or idling the vehicle. Review the GDS2 data to ensure the charging
system is operational.
13. Refer to G.S.I. Generator Control and Battery Module Replacement and Shipping Preparation.
Note: The Generator Control Module Cable Cover (Manual Service Disconnect Cover) should remain with the
vehicle and not be returned with the battery assembly. The MSD switch on the power pack should be zip tied in the
open position and the high voltage 3 phase cable connections and 12V cable connection should be covered with
UL® listed, or equivalent, insulation tape rated at a minimum of 600V for return shipping.
Danger: The high voltage (HV) battery must be protected when outside of the vehicle. This is why the battery
must be immediately placed inside the plastic shipping bag and the original shipping container.
STORAGE GUIDELINES:
1. Store the Drive Motor Generator Control and Battery Module flat on a level surface.
2. Store the Drive Motor Generator Control and Battery Module in an environmentally protected area.
3. Maintain the Drive Motor Generator Control and Battery Module at room temperature.
4. Protect the Drive Motor Generator Control and Battery Module from exposure to liquids.
5. Protect the Drive Motor Generator Control and Battery Module from physical damage.
6. Store the Drive Motor Generator Control and Battery Module in a limited-access area.
CANADA ONLY- Parts Return Request (Core Return) - For dealers in Canada, the return of failed batteries will be
handled through the existing core return process. (Type 4 return)
SHIPPING PREPARATION:
1. Disable the high voltage at the Drive Motor Generator Control and Battery Module. Refer to High Voltage
Disabling
2. Remove the Drive Motor Generator Control and Battery Module from the vehicle as outlined in Generator
Control and Battery Module Replacement in G.S.I.
3. Tighten any fasteners that were loosened or removed during Drive Motor Generator Control and Battery Module
removal to the original torque specification
4. Write the TAC case reference number on the Drive Motor Generator Control and Battery Module in a visible
location
5. Write the TAC case reference number on the repair order
6. Ensure that tape with UL® listed, or equivalent, insulation tape rated at a minimum of 600v covers the high
voltage 3 phase cable connections and the 12 volt DC cable connection.
7. Ensure the Manual Service Disconnect (MSD) is properly retained in the open position with a zip tie.
8. Place the Drive Motor Generator Control and Battery Module into the plastic shipping bag and original shipping
container.
9. Place a copy of the completed repair order with any technician comments, inside the shipping container with the
failed battery.
10. Close the top lid and adhere using the two Velcro straps.
3775124
CANADA DEALER SHIPPING INSTRUCTIONS:
Canadian Dealers should follow the steps below to return a failed battery:
1. Submit a type 4 core return for the battery.
a. A core return tag along with a core return application will be generated at your servicing PDC and sent to you
2. Place the core return tag on the outside of the battery container.
3. Secure shipping container to the shipping pallet with reusable straps.
Note: DO NOT return the battery in any container other than the container that the new/refurbished battery was
delivered in.
4. Complete the required hazardous goods shipping paperwork (302C form).
5. Leave the labeled container along with the necessary shipping documents in the area within your dealership
which you would normally use for your material / core returns. The DDS carrier will pick up this battery core
along with your normal returns. If your dealership is not serviced by a DDS
6. DO NOT return batteries to the ESC in Canada.
US ONLY – Parts Return Request
– You will be contacted with a Special Parts Return Request and proper shipping instructions within two weeks.
PLEASE FOLLOW GUIDELINES BELOW:
1. DO NOT send a Drive Motor Generator Control and Battery Module back without a Special Parts Return
Request.
2. DO NOT send the Drive Motor Generator Control and Battery Module back to the ESC.
3. DO NOT return the Drive Motor Generator Control and Battery Module in any other container thanthe container
that the new/refurbished battery was delivered in. The removed unit must be returned complete in the original
exchange shipping container.
The Special Parts Request will provide a request number. This request number must be placed in the outside
shipping envelope along with the TAC Case number. Do not ship a Generator Control and Battery Module back
without an official Request.
Note: If you do not receive the return paper work, Call GM CCA Logistics: 855-654-7157 (shipper prompt #1) to
obtain the proper paper work in order to return the failed battery Module
U.S. DEALER SHIPPING INSTRUCTIONS:
1. Refer to the Lithium Ion (Li Ion) Battery Warranty Return Process in Global Connect listed under Parts / Process
and Policy / G_0000176282 for detailed shipping information.
2. Place a copy of the Special Parts Return Request, repair order with technician comments and place into the
plastic envelope. The bill of lading and customs papers (for cross border shipments) should also be inserted into
the plastic envelope. Remove the original shipping label and attach the plastic envelope with the return shipping
label on it to the container.
3. Close the top lid and adhere using the two Velcro straps. See photo above.
4. Label the outside of the shipping container with the Part Return request number and the TAC case reference
number.
GM Warranty Parts Center
45 Northpointe Drive
Orion, MI 48359
In the event the HV Battery needs to be recycled, refer to the webpage "General Motors Recycle MyBattery” http://
recyclemybattery.com/ for the latest information.
Warranty and customer pay batteries that are not compromised should be returned to the ESC or WPC as
requested.
Parts Information
YEAR / MAKE / MODEL
COMPONENT CODE
PART NAME
2012 Buick LaCrosse, Regal 2013
Chevrolet Malibu Eco
A4
Generator Control and Battery
Module (PowerPack)
2013-2015 Buick LaCrosse, Regal
2014 Chevrolet Malibu Eco 2014
Chevrolet Impala
A4
Generator Control and Battery
Module (PowerPack)
2012-2015 - All Models
C4A/C4B
Generator Battery Sections 1 And 2
Warranty Information
For vehicles repaired under warranty use:
Labor Operation
Description
Labor Time
Part Allowance
5031400
Generator Control and
Battery
Use Published Labor Operation Time
$250
5031050
Generator Battery
Use Published Labor Operation Time
$150
Add
Administrative
Allowance
.2 Hours
N/A
Add
Road Test - GDS2
Session Log
.3 Hours
N/A
Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is
resolved without completing every step, the remaining steps do not need to be performed.