Hybrid Two-Mode High Voltage Battery Parts Restriction

This bulletin is being revised to add the 2009 model year and the 2009 Cadillac Escalade Hybrid. Please discard Corporate Bulletin Number 07-06-03-008 (Section 06 -- Engine/Propulsion System).

The purpose of this bulletin is to explain the Two-Mode Drive Motor Generator Battery parts restriction program for the 2008-2009 models listed above. The drive motor generator battery assembly is referred to as the hybrid battery. This parts restriction program will be in effect for 6 months. However, this program may be extended up to 1 year to get important feedback on this new hybrid battery assembly. This bulletin will be revised to announce the end of the parts restriction program at a later date.

Product teams continually seek valuable information for engineering improvements. To assist in this effort, a hybrid battery parts restriction program will be used for this product. The 2008-2009 model year Hybrid Two-Mode parts restriction program will be administered by the GM Technical Assistance Center (TAC). The servicing technician must provide detailed customer comments, conditions, diagnostic trouble codes (DTCs) and other useful information. To request a two-mode drive motor generator battery, dealerships are required to call Technical Assistance (TAC). Prior to calling TAC, please make sure to complete the Hybrid Battery Part Restriction worksheet referenced at the end of this bulletin. Use of this worksheet will minimize the time spent on the telephone and avoid the need of a second call to the TAC. Guidelines for honoring parts restriction requests under this program are being strictly enforced.

During this parts restriction period, components inside the high voltage hybrid battery assembly will not be replaced. Do Not remove any high voltage battery assembly covers during this parts restriction period unless instructed to do so. This will minimize exposure to high voltage inside the battery assembly until all of the technician training is completed including internal battery service.

Please note that this hybrid battery parts restriction program is subject to change as the program progresses. You will be notified by the TAC consultant if components inside the hybrid battery assembly are considered serviceable.

Caution: 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.

Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling in SI.

Caution: The high voltage (HV) battery must be protected when outside of the vehicle.

1. A thorough diagnosis must be performed in order to prevent unnecessary component replacements. Refer to Diagnostic System Check-Vehicle with HP2 in SI to identify the correct procedure for diagnosing the system.
2. If DTCs are present and the procedure gives direction to remove internal components; stop, capture snapshot stored data, and test drive the vehicle with the Tech 2® installed and capture a snap shot of the BECM data when a condition occurs. See Service Bulletin 07-07-30-010A for correct snap shot data collection. Call TAC once data has been captured. TAC may request that you e-mail the snapshot to them.
3. If DTCs are not present, refer to Symptoms Hybrid Energy Storage in SI.
4. If any diagnostic procedure gives direction to remove internal components -- Stop . No internal components should be removed at this time.
5. Complete the Hybrid Battery Part Restriction Worksheet referenced at the end of this bulletin and then call TAC.
6. Contact TAC to verify that proper diagnosis has been performed. Upon review of the diagnosis, TAC will establish a case reference number and make arrangements for ordering a hybrid battery assembly unit to your dealership if necessary. DO NOT SHIP A HYBRID BATTERY TO THE WARRANTY PARTS CENTER (WPC) WITHOUT AN OFFICIAL WPC REQUEST.
7. Follow procedures for disabling high voltage systems in SI.
8. After verifying that the high voltage systems are disabled, remove the hybrid battery assembly per SI procedures.
9. Perform Drive Motor Generator Battery Control Module (BECM) reprogramming as well as check and reprogram all hybrid control modules with the latest calibrations.

Important: Failure to return the replaced hybrid battery by the due date will result in the dealership being debited the entire warranty claim (parts and labor). The removed unit must be returned in the original packaging. For effective engineering analysis, please do not remove or disassemble any components.

The Warranty Parts Center (WPC) will issue a Part Return Request at the time of claim payment. DO NOT send a battery back to the WPC without a WPC request. The Part Request will provide a request number. This request number must be written on the outside of the return container using a permanent marker. Failure to write the request number on the return container may delay the processing of your return. Failure to return the battery may result in a debit.

1. Disable the high voltage at the drive motor generator battery. Refer to High Voltage Disabling in SI.
2. Remove the high voltage battery from the vehicle as outlined in Drive Motor Generator Battery Replacement in SI.
3. Tighten any fasteners that were loosened or removed during high voltage battery removal to the original torque specification.
4. Remove any plastic shipping plugs or covers from the new unit and install them on the high voltage battery to be returned.
5. Attach non-spillable label, provided with the new battery, to the top of the failed battery assembly (These non-spillable batteries are exempt from DOT hazardous materials regulations when shipping by ground transportation).
6. Write the TAC case reference number on the hybrid battery assembly in a visible location.
7. Place the hybrid battery core into double polyethylene bags.
8. Write the TAC case reference number on the repair order.
9. Place the high voltage battery core into the shipping container and attach the completed return shipping tag to the high voltage battery.

Important: The failed hybrid battery assembly must be placed in two (double) polyethylene bags that were provided with the new battery. This double bagging procedure must be performed as soon as the battery is removed from the vehicle. After bagging the hybrid battery, place the part in the original shipping container. Hybrid batteries are not to be shipped or returned until all protective covers, which are shipped with the new battery, are installed and double bagged. If the bags were misplaced or discarded, they can be obtained from www.uline.com in bulk. The part number for the bags are S-11050.

1. Place a copy of the WPC request, repair order with technician comments and the completed Hybrid Battery Part Restriction Worksheet 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.
2. Label the outside of the shipping container with the WPC request number and the TAC case reference number. Refer to Corporate Bulletin Number 99-00-89-019E for detailed shipping information. Contact the specified carrier to arrange for pick-up of the removed component. If lift gate service is necessary, please request it at the time of arranging pick-up service.
3. Have the driver sign the bill of lading. Retain a copy of the signed bill of lading and attach your copy to the original repair order. This will be your proof of returning the high voltage battery.
4. Ship the high voltage battery with appropriate paperwork to:

GM Warranty Parts Center

45 Northpointe Drive

Orion, MI 48359

For vehicles repaired under warranty, use:

BATTERY PRODUCT FEEDBACK FORM

Complete the feedback form before performing the high voltage disabling procedure and removing the drive motor generator battery. Using a scan tool where appropriate, record the following information/data from the BECM data lists.

Notice: Multiple Tech 2® Screen prints containing the following information will be accepted in lieu of completing the table below. The information below can be found in the BECM Data Menu on the Tech  2®.