Regenerative Braking Calibration

Calibrate the regenerative braking system on a 2023 Chevrolet Bolt EUV to ensure proper energy recovery and seamless transition between regenerative and friction braking.

Warnings

Tools required

Fluids

• ACDelco DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Connect 12V battery maintainer to 12V auxiliary battery to prevent voltage drop during calibration
4. Verify high voltage battery state of charge is between 30-80% using instrument cluster display
5. Ensure brake fluid level is within normal range; top off with ACDelco DOT 4 if needed
6. Clear any existing diagnostic trouble codes and verify no ABS, traction control, or brake system warnings are present
7. Close all doors, hood, and liftgate to prevent interruption during calibration

Procedure

1. 1

   Connect diagnostic equipment
   Connect the GM MDI 2 diagnostic interface to the vehicle's OBD-II port located below the driver's side dashboard. Launch GM SPS software on laptop and establish communication with the vehicle. Verify connection to the EBCM (Electronic Brake Control Module), PCM (Propulsion Control Module), and HPCM2 (High Power Charging Module 2).
2. 2

   Perform pre-calibration system check
   Using the diagnostic tool, navigate to EBCM and verify all brake pressure sensors are reading normally (0-5 psi with brake pedal released). Check wheel speed sensor readings to ensure all four sensors report 0 mph with vehicle stationary. Verify brake pedal position sensor shows 0-2% travel with pedal released. Document any out-of-range values before proceeding.
3. 3

   Check regenerative braking components
   Navigate to the Propulsion Control Module and verify motor resolver/encoder readings are stable. Check coolant temperature is above 60°C (140°F) for optimal calibration. Verify the brake booster vacuum sensor (electric vacuum pump) is functioning normally and showing proper vacuum levels between 18-22 inHg.
4. 4

   Initiate regenerative brake calibration routine
   In GM SPS software, navigate to Service Programming System > Vehicle Programming > Calibrations. Select 'Regenerative Braking System Calibration' from the EBCM calibration menu. Follow on-screen prompts to begin the automated calibration sequence. The system will perform a series of self-tests with the vehicle stationary.
5. 5

   Perform brake pedal position learning
   When prompted by the software, do not touch the brake pedal. The system will learn the released pedal position for 30 seconds. Next, when instructed, slowly depress the brake pedal to full travel and hold for 10 seconds. Release slowly and allow the EBCM to learn the full pedal travel range. Repeat this process three times as directed by the software.
6. 6

   Execute brake pressure sensor calibration
   The software will command the hydraulic control unit to cycle through various pressure points. You will hear the ABS pump activate and relays clicking - this is normal. The EBCM is calibrating pressure sensor zero points and establishing baseline values for regenerative-to-friction brake blending. This process takes approximately 5-7 minutes and must not be interrupted.
7. 7

   Perform road test calibration sequence
   Following software instructions, prepare for a road test. Ensure traffic conditions allow for safe acceleration and deceleration. Drive the vehicle following the on-screen prompts: accelerate to 35 mph, release accelerator completely and allow regenerative braking to slow the vehicle to 5 mph without touching brake pedal. Repeat this sequence 5 times. Then perform 3 moderate brake applications from 35 mph to complete stop using brake pedal to calibrate blending.
8. 8

   Complete maximum regeneration calibration
   Set the drive mode to 'One Pedal Driving' mode using the center console button. Accelerate to 40 mph on a safe, level road. Completely release the accelerator pedal and allow maximum regenerative braking to slow the vehicle to a complete stop without touching the brake pedal. Repeat 3 times. The system is learning maximum regenerative torque capacity and calibrating the seamless transition to friction brakes at low speeds (below 5 mph).
9. 9

   Verify calibration completion
   Return to a safe parking location. The software will display 'Calibration Complete' when all adaptive learning values have been stored. Review the calibration report for any fault codes or incomplete procedures. Use the diagnostic tool to verify that EBCM shows 'Regenerative Brake Calibration Status: Complete' and no pending DTCs are present.
10. 10

    Final system verification
    Clear the diagnostic tool connection and perform a final functional test. With vehicle in Drive on level ground, verify smooth regenerative braking when releasing accelerator pedal. Check that brake pedal feel is firm and consistent. Verify the instrument cluster shows proper energy regeneration feedback (green arrows pointing down to battery icon) during deceleration. Test One Pedal Driving mode for smooth engagement.

Reassembly

1. Disconnect 12V battery maintainer and verify 12V battery voltage is above 12.4V
2. Remove wheel chocks and store all tools
3. Document calibration completion date and mileage in vehicle service records
4. Reset trip meter or make note of current odometer reading for future reference

Verification

• Perform test drive and verify regenerative braking engages smoothly when releasing accelerator with no harsh transitions
• Confirm brake pedal feel is consistent and firm with no sponginess or unusual travel
• Verify instrument cluster displays regenerative braking activity (energy flow animation) during deceleration
• Check that One Pedal Driving mode brings vehicle to complete stop smoothly without driver needing to apply brake pedal on level ground
• Confirm no ABS, brake system, or traction control warning lights are illuminated on instrument cluster
• Use diagnostic tool to verify no DTCs are stored in EBCM, PCM, or HPCM2 modules
• Verify brake fluid level remains in normal range after calibration procedure

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