Perform a complete EV system reset and calibration on the 2023 Chevrolet Bolt EUV, including high-voltage system de-energization, module diagnostics, battery management system reset, and post-calibration verification.

Warnings

Tools required

Parts

• High-voltage connector service caps (if damaged) × 2 — GM 23489476 or equivalent
• High-voltage safety labels (replacement) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface in well-ventilated area and apply parking brake
2. Place safety cones and warning signs around vehicle to prevent unauthorized access
3. Verify vehicle is in PARK and turn ignition to OFF position, remove key fob from vehicle interior
4. Connect 12V battery maintainer to 12V auxiliary battery to prevent system dropout during procedure
5. Allow high-voltage battery to reach ambient temperature if vehicle was recently driven (wait 30+ minutes)
6. Put on appropriate PPE: high-voltage safety gloves, safety glasses, and non-conductive footwear
7. Connect GDS2 diagnostic tool and establish communication with all vehicle modules
8. Perform complete system scan and record all DTCs, freeze frame data, and battery health parameters

Procedure

1. 1

   De-energize high-voltage system
   Using GDS2 scan tool, navigate to Energy Storage System module and initiate controlled shutdown. Verify all contactors open. Turn ignition OFF. Open rear cargo area and remove cargo floor cover. Locate high-voltage battery service disconnect (orange-colored connector on passenger side of battery pack). Remove protective cover by loosening cover screws. Using insulated tools, rotate service disconnect handle counterclockwise 1/4 turn and pull straight out to remove.
   ⚠️Ensure vehicle has been OFF for at least 30 seconds before opening service disconnect. Verify contactor status on scan tool shows OPEN.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Verify high-voltage de-energization
   Wait minimum 5 minutes for high-voltage bus capacitors to discharge. Using CAT III rated multimeter, measure voltage across high-voltage bus at the service disconnect location. Verify reading is less than 3V DC. Measure again at drive motor power inverter connections (accessible from under-hood). Document all voltage readings. If voltage exceeds 3V, wait additional 5 minutes and re-test.
3. 3

   Disconnect 12V auxiliary battery
   Open hood and locate 12V auxiliary battery in front compartment. Remove negative terminal first using 10mm socket, then remove positive terminal. Isolate both cables away from battery posts. Wait 2 minutes for all control modules to fully power down and clear volatile memory.
   ⚠Some stored calibrations and radio presets will be lost. Ensure customer is aware before proceeding.
4. 4

   Inspect high-voltage connections and components
   With system de-energized, visually inspect all accessible high-voltage connectors (orange cables) for damage, corrosion, or loose connections. Check drive motor power cables, onboard charger connections, and battery pack main connectors. Inspect connector seals and locking mechanisms. If any high-voltage connector bolts were previously loosened or service was performed, verify torque specifications. Remove any corrosion with approved contact cleaner.
   ⚠Even with system de-energized, treat all orange cables as live until verified with multimeter at each connection point.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
5. 5

   Reconnect 12V battery and initialize scan tool
   Reconnect 12V auxiliary battery, positive terminal first, then negative terminal. Ensure connections are tight. Turn ignition to ON position (do not activate READY mode). Connect GDS2 scan tool and verify communication with Body Control Module, Energy Storage System Control Module, Drive Motor Control Module, and Onboard Charger Module. Check for any new DTCs related to high-voltage disconnect.
6. 6

   Clear fault codes and reset battery management system
   Using GDS2, navigate to Energy Storage System Control Module. Select 'Clear DTCs' to remove all stored fault codes related to service disconnect. Navigate to Special Functions menu and select 'Battery Energy Control Module Reset'. Follow on-screen prompts to reset battery state of charge algorithm, cell balancing parameters, and thermal management baseline. This process takes approximately 3-5 minutes.
7. 7

   Perform drive motor position sensor calibration
   Navigate to Drive Motor Control Module in GDS2. Select 'Special Functions' then 'Resolver Calibration'. Ensure vehicle is in PARK on level ground. Follow scan tool prompts to perform resolver/position sensor auto-calibration. System will energize motor control circuits (NOT high-voltage) to learn sensor positions. Process takes 2-3 minutes and will display completion status.
8. 8

   Reset onboard charger and DC fast charge system
   Navigate to Onboard Charger Control Module. Select 'Module Reset' to clear adaptive charge parameters. Navigate to Special Functions and select 'Charge Port Communication Reset' to recalibrate charge port pilot signal and CAN communication. For DC fast charge system, select 'DCFC Contactor Learn' to reset high-power charging contactor operation parameters.
9. 9

   Calibrate thermal management system
   Navigate to Thermal Management System Module. Select 'Coolant Flow Calibration' to reset battery cooling system valve positions and pump parameters. Select 'Temperature Sensor Offset Learn' to baseline all battery pack temperature sensors. Ensure coolant level is correct (10 quarts DEX-COOL Orange). System will run cooling pump at various speeds for approximately 5 minutes.
10. 10

    Perform brake system integration reset
    Navigate to Electronic Brake Control Module. Select 'Regenerative Brake Calibration' to reset the integration between regenerative braking and friction brakes. With vehicle in PARK, brake pedal released, execute calibration. System will cycle brake pressure modulator valves and learn brake pedal position sensor baseline. Verify brake fluid level is at MAX (DOT 4).
11. 11

    Reconnect high-voltage service disconnect
    Return to rear cargo area with high-voltage disconnect removed. Inspect disconnect mechanism for damage or debris. Align service disconnect and insert straight into receptacle until fully seated. Rotate handle clockwise 1/4 turn until locked. Verify locking indicator shows green/locked position. Reinstall protective cover and tighten cover screws to specification.
    ⚠️Ensure disconnect is fully seated and locked before proceeding. Improper installation can cause arcing and severe damage.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Verify high-voltage system energization
    Using GDS2, monitor Energy Storage System module data. Turn vehicle to READY mode. Observe scan tool as high-voltage contactors close. Verify high-voltage bus voltage rises to pack voltage (typically 340-400V depending on state of charge). Check for any new DTCs. Verify drive motor controller shows READY status. Monitor battery pack temperature sensors for proper readings (should be near ambient).
13. 13

    Perform system function verification tests
    With vehicle in READY mode, use GDS2 Special Functions to perform output tests: Drive Motor Test (verify motor spins freely with no abnormal noise), Onboard Charger Test (verify charger initializes), Cooling Pump Test (verify pump operates at low and high speed), High Voltage Heater Test (if ambient temp below 15°C). Monitor current draw and voltage during each test. All tests should complete without faults.
    ⚠Ensure vehicle wheels are chocked and transmission in PARK during drive motor output test.
14. 14

    Perform drive cycle and final calibration
    Exit GDS2 Special Functions. With vehicle in READY mode, drive vehicle on level road at varying speeds (0-60 km/h) for minimum 15 minutes to allow all systems to complete adaptive learning. Include multiple acceleration and regenerative braking events. Return to service bay and connect scan tool. Verify all system modules show READY status and no pending DTCs. Record final battery state of health, capacity percentage, and all module software versions.

Reassembly

1. Reinstall cargo floor cover in rear storage area
2. Verify all high-voltage warning labels are intact and legible, replace if damaged
3. Remove 12V battery maintainer if used
4. Clear any service mode indicators on instrument cluster using scan tool

Verification

• Scan all modules with GDS2 and verify zero DTCs present in all high-voltage systems
• Verify state of charge display matches actual battery charge level (within 5%)
• Test regenerative braking function by coasting to a stop from 40 km/h and observing energy regeneration on display
• Verify propulsion power is available by accelerating moderately and checking for smooth power delivery
• Test Level 1 or Level 2 charging function to confirm onboard charger operates correctly
• Verify all instrument cluster indicators function properly including battery range estimate
• Print diagnostic report from GDS2 showing all calibrations completed successfully and save to vehicle service record
• Road test vehicle for minimum 10 km to ensure all systems operate normally under real-world conditions

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