A real pleasure to watch you work. Your explanations are clear, complete, and concise. Your camera work is very good also, showing exactly what needs to be shown. Thank you for your series on the 2017 Bolt EV teardown.
Making use of the ua-cam.com/users/postUgkxcJ22tnHH9l1vjdIdEIG27iOG55P7LXI8 reconditioning plan, I just saved 2 auto batteries from being completely junked. The guides were very simple to follow. I wish I would have found this years ago! You may use the guide to recondition any battery type
I have enjoyed your videos immensely as a past auto mechanic and industrial electrician the EVs pull it all together. I use to teach arc flash safety and would joke about the under 50 volt rule minimum safety gear was needed, I guess they never saw a 12 volt car battery explode. I can only imagine what kind of energy would escape while plugging those connectors in if something went wrong. Watching the news one day they showed a car driving through deep water and explode, I thought to myself it has to be an EV. Keep up the good work.
Hi, first of all thank you very much for these excellent videos, knowledge and educational programme. I just wanted to mention that in some electrical vehicles after disconnecting the service fuse you have to wait 10 minutes or so before starting/carrying/inspection for any work. I believe we have to wait for the capacitor to fully discharged or de-energised. Correct me if i'm wrong. I noticed soon after you disconnected the service fuse you went straight to check for voltage in the inverter. many thanks.
Firstly, a very well done series of videos. The one thing I did notice is that your probe tips were set to category 3 when you were calling them category 4 and vice versa. The higher the category number the less exposed metal at the tip. I'm curious why they specified those specific ratings. In my field (electrician) category increases as you get closer to the source due to higher risk of transients. I wasn't aware that there would be a risk of transients at all coming from a battery pack. Either way I'd have my probes set to cat 4 with all that available power. Less metal, less chance to cause an accidental short. Thank you again for this wonderful series.
Dude you are a BEAST!!!! BEASTMAN I'm 33 and still struggling with being an out of work engineer in Nigeria, but seeing you work motivates me to build a better future for myself systematically. I need to perfect a skill to become invaluable as you are sir. You seem to move so smoothly, watching you work is like watching Kobe Bryant paint on the basketball court. As far as EVs go, I do believe that they are the future as long as battery supply can keep up with demand. Overall, they seem so simply and efficient. Anyways, back to my entrepreneurship work.
I await your tear-down of this pack. I noticed the tapered seam between the two halves of the pack and can only guess that this is to improve water and debris run-off which will reduce corrosion on the MANY bolts holding the two shells together. The label you could not identify its purpose on the top appeared to be a material label. GF45 sounds like Glass-Filled 45% to me. GM used a patented (or possibly trade secret) material on the Chevy Spark pack and this looks like the same fiberglass-reinforced material used on that pack. It’s light. It’s strong. It’s also expensive.
Great video! I appreciate the time you take to capture and explain every detail. This is like the show Ask This Old House for automobiles. Is there is no aerodynamic defuser (cover) underneath the Bolt? The battery pack, cables, and lines are all exposed to the elements if there is not cover. Here in the Northeast, all the salting of the roads and highways will take a toll on them. Fossil fuel vehicles can't have a full cover because of the exhaust pipe, catalytic converter and muffler being very hot. But fully electric vehicles can.
Thank you! There is a large under-vehicle cover for aerodynamics and protection of all under car components. I neglected to mention that I had already removed it for this video. I will show it in the next video when I disassemble the entire battery pack. Have a good day!
Thanks for the well explained sequence there. I think I would not leave the high voltage connector hanging down into the coolant bucket while removing the fitting. A splash onto that connector and you may find yourself wondering how you’re going to clean it. Also it’s possible that there could be a lot more coolant in that pack than you think and it simply fills the bucket up until the connector is dunked. So I’d push it out of the way before disconnecting. Otherwise a great procedure well explained.
Great point, I should have had that out of the way. Luckily it did not get splashed on. The rest of the coolant (3.8L) was removed from the battery in the next video on battery disassembly. See ua-cam.com/video/ssU2mjiNi_Q/v-deo.htmlm49s Thanks for your feedback.
Wow! That battery is small for so much capacity. Sorry to hear you had the flu. It got me too this year, really kicked my behind. Hope you're feeling better. It took me a few weeks to get back up to speed. And, yes, I'm really looking forward to the Volt driveline teardown.
Hi Professor Kelly, First let me compliment you on your series of videos on the Chevrolet Bolt. I have watched everyone and learned a lot. They are great because they make the complicated seem simple. That is a talent. Thank you. I have also watched several of your videos on the Prius. Again you did an excellent job of making the sophisticated simple. I have a request. Would you consider demonstrating, on a video, the installation of a 12 VDC to 120 VAC inverter into the Bolt? I believe in order to make this work as a backup emergency system the Bolt needs to be on? Again thank you for very interesting, detailed and thorough videos. Leo
With your deep insight into the vehicle do you feel there are areas that could potentially be susceptible to fire risk? I ask because one caught on fire close by yesterday and I am wondering if there are any additional precautions us Bolt owners can take to minimize potential fire risk. I have on video on my channel describing the one that caught fire yesterday if you are curious. Thank again for the information you have provided in your videos, it is greatly appreciated.
I admire your ability to work on these things. The more I watch your videos on the Bolt, the more I like it... The quality, logical design and easy of assembly of this car make me want this car more and more... I have a Nissan Leaf and it does not appear to be of such high quality..
Thank you very much Professor, really enjoyed the training video, the quality audio and pristine video made for riveting viewing, once again a big thanks from Scotland cheers sandy
Fortunately in a collision, most of these systems are disabled automatically. However emergency personnel would be wise to understand basics. The first few steps are similar to our Lexus hybrid, with the same orange color for high voltage wires.
I'm thinking about getting a used Volt but the transmission is over complicated. It's a great idea, but have any common issues developed in the volt? I like the simplicity of an EV better but I can't afford a new Bolt
I have not heard of any common issues with the Volt transmissions. My 2014 Volt has 50k miles on it without any issues. My 2012 Volt was also trouble free. My co-worker bought a used 2012 Volt with 100k miles on it. It also has no issues. Best wishes.
I am EXTREMELY surprised that there is no protection plate under the volt for protection of the battery and all those hoses. Tesla learned that lesson and now every Tesla has a titanium cover underneath. Also helps with aerodynamics.
ENCORE-----Please further instruct on how to install the battery, its connections , the lower cover and the operational checkout. GM needs to produce some service manual series and soon! THANKS.....
Mr. Kelly thank you for the video I always watch your videos they're very affirmative could you please tell me the scissor lift is it OTC please let me know cuz I'm going to purchase one for my shop thank you sir
Did you happen to notice on the underside, there is approximately 80% of a spare tire well (don't believe this is capture? I'm still scratching my head on that one. I believe with fast charging the power is transferred through the same large cables that connect the battery and controller(?). GM manufacturing Bolts w/out DCFC is unfortunate. I own a Spark EV w/ DCFC. You do good work sir, thank you for sharing.
Thank you! I have not looked in the compartment on the car yet. It does look like a spare tire area, but it is probably just storage. I just verified it, you are absolutely correct. When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector is only used when using a Level 1 or Level 2 AC J-1772 charger connector. Thanks again, have a great day!
Although it looks like a spare tire well, one would definitely NOT fit. However, a factory wheel with a tire fits just about perfect under the false floor if you have the option or bought it aftermarket. The well has a big foam block which provides storage for the recovery hook, the optional (?) air compressor, and 120 volt charging cord.
John, would you PLEASE make a UA-cam video explaining how to understand and charge The Chevy Bolt all 3 levels.. I've watched so many videos that are vague about how to plan a trip for charging.How much time it will take to charge. Even charging to 67 %, then moving on. I'm so trying to learn how to know if a charger even works by the time you arrive to recharge on these long distant trips in the bolt EV. You explain things so well. So many people would benefit from your shared knowledge. Thank you,
Thank you for the video. I'm looking to buy one of these and expecting to have to change the battery in 10 years. Seems easy enough with the right tools.
Just finished watching, now i can go to sleep! Always a great pleasure to watch your beautifully made and professional lessons, I'm really looking forward to the next video!
Really it is very interesting course which video and audio quality which very clear and simple explication method I like it well. Good job professor and thank you very much. JLR technician from Morocco🙏🏻
Dear Professor, I noticed you work alone most of the time. As a suggestion, for safety reasons, would be good for you to have some companion. Thanks for posting and share!
I’ve watched hours of your videos and 5:40 is the first time you’ve appeared upset. It’s alright to swear, Professor.....I do it all the time when trying to figure out what the holy hell so-called engineers were thinking. Thank you, and keep up the good work!
Dang, thats actually really easy to do provided you have something that can hold and move the battery. I can see doing it without a lift if you have some heavy jacks and a really well made cart.
Thank you so much for the great video. I am surprised the bolt has such a thin battery design comparing to BMW i3. I guess the reason behind is the drive train layout? So I guess the bolt is front wheel drive, which Chevy could fit the motor under the hood, and free up the space under rear seat for batteries and control module. And i3 is rear wheel drive, so the space under rear seat and trunk is taken out by the motor and optional generator, so the battery has to be a relatively flat module to fit under the floor, also it can't stick out too much in front in case of frontal collision, don't want to damage the batteries and control module. But still just look from the outside the LG cells in Chevy Bolts seems to be a lot shorter(thinner) than the Samsung cells in BMW i3
Luke W I do like the Samsung cells on i3, already have 50k miles on it, estimate capacity lost is around 1%. But the range is kind of short, not very impressive
Guo Richard good to hear you are driving an i3. Yes 60ah without a heat pump isn't great especially as the cat isn't very aerodynamic. But it's fun to drive and you can swap to higher capacity battery pack easier than most.
Professor John Kelly. I’m fascinated about You explains Your dissecting the different cooling passages, different bearing types, grease, oils, antifreeze coolant. This unit was from a fire damaged 2026 MODEL S. You do a much more detailed explanation than Sandy Munro. I’m sure You would both have total respect for each other’s analysis. I would like to know how this motor evolved starting in 2012 with probably many prototypes with failures, and redesign and to a product that will last more than 20 years. My observations are how unique the requirements for sealing are which are much more complicated than any Gas Engine. The seals used and routing of coolant both internally and externally to
Continued. To Super bottle and then Octo Vakve. Many Questions: How many types of motors, drive trains, and did they élever have catastrophic failures on this developing process to engineering excellence. I’m waiting for CYBERTRUCK DUSL MOTOR. Thank You.
You're an inspiration. So intelligent and thorough videos keep up the great work and educate us on those wonderful electric cars. Thanks for training future technicians
Great detail as always, Professor Kelly! Would you consider having the B(ravo)olt over your V(ictor)olt?? Assuming of course you still own Victor... Also, there seems to be an awful lot of surface area with all the webbing in the under structure of this car. Could that present issues in the future with corrosion as I see lots of places for road salt, etc to live. I'm wondering what you think? 👋🏻
Thank you! I would like a Bolt. I would still keep my Volt. The lower tray is 0.050" (1.27mm) thick. The webbing is 0.094" (2.39mm thick). It is made to withstand running over objects without penetration. I think It will be okay. Thanks for your feedback.
Excellent video however I would be concerned about the car shifting or possibly falling off the lift due to front heavy weight distribution-perhaps strapping the rear of the car to the lift would solve this issue
Very well done. Your patience is remarkable. You explain technical aspects very well, a nice balance of clarifying concepts in some instances while seemingly having expectations that the listener is an educated layman that does not need handholding. This topic is highly interesting to this retired white collar guy who likes getting hands dirty turning wrenches. Being convinced that EV is the solution to the near future, I dare say that very many find your topics of great value. You are trail blazing what I contend is one of the most important technical maintenance areas into the rest of the 21st century. Thanks, as well to Weber State for supporting you in bringing your channel to life!
I was hoping you would pop the top and get a peek! I that battery pack serviceable? Can individual cells/packs be replaced? Thanks for the video, interesting.
I will pop the top in the next video and totally disassemble the entire battery pack. Thanks for your feedback! Individual cells cannot be replaced. Only the battery modules.
Amazing Video. love how clearly you showed and detailed that for us. Great insight! With the Big GM recall of those LG Chem batteries, its great to know what they will actually be doing to our cars. Thank you!
Lifting the last section high enough to look under, it is visible how inefficient the contact is with the thermal transfer pad! [assuming the darker color is the stain on the metal from the adhesive, and the lighter metal has not come in contact at all?]
Paul Wicklund that and all the salty slushy sandy snow in mn will wreek havoc on those connectors and such underneath unless there is some kind of shield covering them?
GM has an undercoating solution for the Bolt, and I imagine that, once out of warranty, you could get away with any non conductive corrosion resistant product like Rust Check or Corrosion Free. I know that some people think that undercoating is a "scam", but those of us who live in the rust belt know for a fact that even on new cars, it's 100% a yearly requirement.
I live in the mag chloride belt and after a day out in the slush I always stop at the nearby car wash for a drivethrough underside washout. Then the heated garage.
Absolutely amazing step by step learning video. Thank you for taking the time and consideration in putting this video together. Please keep up the great work.
Thank you for this fascinating video. I was wondering what the labor hours would be to have this done at a dealership? In some ways it seems easier than a normal engine removal, but more difficult in others. Will these cars see multiple owner paid for battery packs in respective their lifetimes, thus making them viable to operate economically well past the normal 150-250K mile service life we see today?
Thank you! Now that I see how easy it is to swap out the battery, I suspect it would take 2 hours labor for the complete job. I also suspect the batteries will last well beyond 100k miles. The rest of the Powertrain is pretty simple. Not much to go wrong mechanically.
WeberAuto yes, I think the batteries are reliable enough, I have a 2014 BMW i3 Rex, already put 50k miles on it, so far I have the exactly the same range as I bought it 3 years ago. And few days ago in the i3 FB group, someone actually just hit 100k miles on the original battery, and lost about 4% of the capacity.
This couple of years video is coming in handy with the Bolt EV recall of Friday November 13, nobody know at this point what is going to be the final solution to the “ battery fire”problem. But if it is a battery replacement at least we know what they will be doing and what is going to fail in the car next (probably the coolant pump seals, for not removing air) after the battery replacement is done. Not sure if the technicians at my Chevy dealer are going to be able to do this with the finest of the profesor.
GM Warranty time always CHEAP !!! I worked on the 2004 Silverado MILD HYBRID - START STOP only paid 4 hrs to replace the Burnt out Stator Bad DESIGN , had lots of battery Codes
Did you ever figure out what the leak from the steering gear was? My Bolt has a binding steering gear and my friend and I have been arguing about how the rack might have failed, and I remember you spotted a leak near your steering gear. Did you ever diagnose it? GM would claim it's wax in this TSB - 16-NA-109. But it seems counter intuitive that the steering gear would use oil vs grease.
Keeping lithium ion batterys 30-80% charged greatly extends their useful life. This is the long life trick for your smartphone (charge for 30min at a time), tablet, laptop, smartwatch etc! Regular 100% charging of lithium ion batteries causes shrink swell damage to the cathode (lithium cobalt) and anode (hard carbon) ; causing a progressive accelerated loss of capacity
Any thoughts about the charge controller & BMS in hybrid & electric vehicles protecting the large expensive batteries from overcharge damage ? Toyota already proved that 20-90% charging greatly enhances the battery lifetime of NiMH and Lithium Ion batteries in their hybrid vehicles!
Your a very polite & responsive channel moderator. Thank you for always giving kind responses. I would be honored to meet you & visit the facility where you have all these cool hybrid & electric vehicles being taken apart & put back together! Super cool! Thank you for posting these edifying interesting well made videos! Cheers
Thankfully, the Bolt has a feature to extend the life of the battery. In the Energy Section of the radio, go into the menu and enable Hilltop Reserve if you can spare about 20 miles of range. This will change the "Full charge" from 100% to 90%. The true purpose of this feature is to enable extra regen capacity for those that live on top of a hill, but it works great for extending the life of the battery when you don't need a completely full charge. It's even location-based if you want so that the Bolt will fully charge if you charge away from a certain location or only at a certain location. I understand newer Bolts allow more control of the full charge cutoff point, similar to how Tesla accomplishes this.
Thank you, Professor. You mentioned there are two battery designs and that this Bolt does not have the fast DC charging option. I don’t see a fast charge connector on this pack. 1st Q: Do you know if the other pack design is for the fast DC charging or why there would be two pack designs for this vehicle? 2nd Q: Where are you getting your service information from? Do you have a subscription or were you able to purchase a service manual? I was hoping to obtain a service manual for the Bolt, myself.
Thank you! Correction to my video: When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector shown in the video is only used when using a Level 1 or Level 2 AC J-1772 charger connector. I am getting the battery pack design information from the Chevrolet Service information. It shows the New Design Battery Pack being installed in Vehicles built after 1G1FX6S06H4163254. The first design battery has two female coolant connections at the battery. The first design also has the service disconnect lever (under the back seat) as opening from the driver's side of the vehicle rather than opening from the passenger side of the vehicle. The EPA Service information act of 1995 requires that all factory service information be made available online. You can see all of the service information prices and links here www.nastf.org/i4a/pages/index.cfm?pageid=3291 Paper service manuals are no longer available. Best wishes!
I was wrong in my previous comment to you. I have edited it to be correct. When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector is only used when using a Level 1 or Level 2 AC J-1772 charger connector.
WeberAuto Thanks, again. The second design must have been some poke-yoke-ing to eliminate goofs at the manufacturing plant as the differing ports prevent mis-assembly. I can only surmise that the reversal of the service disconnect was for another optimization improvement. Thank you for the service link. It seems all automakers have gone this route. Pricey for the garage mechanic (I still like to do my own brakes, you know!).
Hello, I have some detailed questions: When should we add oil to the engine? For example, I added oil 1 year ago and it still shows 90%, should I change the oil in this case? , also, when is it better to charge the battery, should it sit until the end and then charge? If, for example, the battery shows 50%, 60% or something else, then can it be charged? Which is better for battery care? And another question, how many amperes is better to charge the car?
Speaking of the 12 volt battery: is it a "standard" lead acid type? I've long wondered why, with hybrids and election seeming to be the greatest thing since sliced bread "they" don't save some weight and gain some capacity by replacing the lead cell with a Li cell in even the most "conventional" automobile.
It is a special kind of lead-acid battery, an Absorbant Glass Mat (AGM) battery. They have very high energy density for their size compared to other battery types, but they are also very heavy.
Cost, I think. It does seem a bit odd as a lithium pack of the same capacity would be about 1/3rd the weight, and weight matters on EVs. But it would cost at least 3 times as much and so far no-one seems to have gone for this. It's also true that all the standard 12V parts are designed for lead-acid voltages so it's just easy. You really need to use 4x3.3V LFP cells to get a more-or-less equivalent LA/AGM voltage, as opposed to the more typical 3.6V (3.0-4.1V) of most lithium chemistries (4x3.6V (14.4V) is a bit high, and 4*4.1V (16.4V) charge voltage is definitely too high. )
A real pleasure to watch you work. Your explanations are clear, complete, and concise. Your camera work is very good also, showing exactly what needs to be shown. Thank you for your series on the 2017 Bolt EV teardown.
Making use of the ua-cam.com/users/postUgkxcJ22tnHH9l1vjdIdEIG27iOG55P7LXI8 reconditioning plan, I just saved 2 auto batteries from being completely junked. The guides were very simple to follow. I wish I would have found this years ago! You may use the guide to recondition any battery type
Sir I just found your video's. All I can say is you were born to teach. You're an excellent instructor.
Wow, thank you!
I have enjoyed your videos immensely as a past auto mechanic and industrial electrician the EVs pull it all together. I use to teach arc flash safety and would joke about the under 50 volt rule minimum safety gear was needed, I guess they never saw a 12 volt car battery explode. I can only imagine what kind of energy would escape while plugging those connectors in if something went wrong. Watching the news one day they showed a car driving through deep water and explode, I thought to myself it has to be an EV. Keep up the good work.
Thanks so much for this. I'm a 2017 owner. Just got the battery recall replacement completed. This explains everything that was done. So cool!
😊😊
Outstanding training video that can't be found anywhere except here with great Professor John Kelly. Thank you sir.
That man can work faster and harder in a wheelchair than most of these cry baby technicians we have in dealerships these days great video sir
Thank you! I enjoy it.
Chad I thought same thing, u said it brother!
Wrong.
Very right 🙌
Hi, first of all thank you very much for these excellent videos, knowledge and educational programme. I just wanted to mention that in some electrical vehicles after disconnecting the service fuse you have to wait 10 minutes or so before starting/carrying/inspection for any work. I believe we have to wait for the capacitor to fully discharged or de-energised. Correct me if i'm wrong. I noticed soon after you disconnected the service fuse you went straight to check for voltage in the inverter.
many thanks.
Prof. Kelly, thank you so much for the educative piece. Technology is really turning around the traditional internal combustion engine we know.
Thank you
The Bolt has only ~30 miles and you are already taking it apart... Excellent! I enjoy watching your videos!
Yes sir! It is a lot of fun (and clean). Thank you!
Excellent video; very clear and illustrative. Congratulations Professor John D. Kelly
Firstly, a very well done series of videos. The one thing I did notice is that your probe tips were set to category 3 when you were calling them category 4 and vice versa. The higher the category number the less exposed metal at the tip. I'm curious why they specified those specific ratings. In my field (electrician) category increases as you get closer to the source due to higher risk of transients. I wasn't aware that there would be a risk of transients at all coming from a battery pack. Either way I'd have my probes set to cat 4 with all that available power. Less metal, less chance to cause an accidental short. Thank you again for this wonderful series.
Thank you and thanks for your feedback. I may have mixed those up while shooting the video. You are correct, shorter tips for higher power levels.
Dude you are a BEAST!!!!
BEASTMAN
I'm 33 and still struggling with being an out of work engineer in Nigeria, but seeing you work motivates me to build a better future for myself systematically. I need to perfect a skill to become invaluable as you are sir.
You seem to move so smoothly, watching you work is like watching Kobe Bryant paint on the basketball court.
As far as EVs go, I do believe that they are the future as long as battery supply can keep up with demand. Overall, they seem so simply and efficient. Anyways, back to my entrepreneurship work.
I await your tear-down of this pack. I noticed the tapered seam between the two halves of the pack and can only guess that this is to improve water and debris run-off which will reduce corrosion on the MANY bolts holding the two shells together. The label you could not identify its purpose on the top appeared to be a material label. GF45 sounds like Glass-Filled 45% to me. GM used a patented (or possibly trade secret) material on the Chevy Spark pack and this looks like the same fiberglass-reinforced material used on that pack. It’s light. It’s strong. It’s also expensive.
Thank you and thanks for the additional information!
Great video! I appreciate the time you take to capture and explain every detail. This is like the show Ask This Old House for automobiles. Is there is no aerodynamic defuser (cover) underneath the Bolt? The battery pack, cables, and lines are all exposed to the elements if there is not cover. Here in the Northeast, all the salting of the roads and highways will take a toll on them. Fossil fuel vehicles can't have a full cover because of the exhaust pipe, catalytic converter and muffler being very hot. But fully electric vehicles can.
Thank you! There is a large under-vehicle cover for aerodynamics and protection of all under car components. I neglected to mention that I had already removed it for this video. I will show it in the next video when I disassemble the entire battery pack. Have a good day!
Thanks for the well explained sequence there. I think I would not leave the high voltage connector hanging down into the coolant bucket while removing the fitting. A splash onto that connector and you may find yourself wondering how you’re going to clean it.
Also it’s possible that there could be a lot more coolant in that pack than you think and it simply fills the bucket up until the connector is dunked.
So I’d push it out of the way before disconnecting.
Otherwise a great procedure well explained.
Great point, I should have had that out of the way. Luckily it did not get splashed on. The rest of the coolant (3.8L) was removed from the battery in the next video on battery disassembly. See ua-cam.com/video/ssU2mjiNi_Q/v-deo.htmlm49s Thanks for your feedback.
God bless you sir, it's amazing to see you work although your in a wheel chair....inspirational.
Thank you kindly
I was going to sleep but your lessons always come first!
Thank you!
I refer all new Bolt EV owners such as myself to your channel. Fantastic!
Thank you very much!
Wow! That battery is small for so much capacity.
Sorry to hear you had the flu. It got me too this year, really kicked my behind. Hope you're feeling better. It took me a few weeks to get back up to speed.
And, yes, I'm really looking forward to the Volt driveline teardown.
Thank you very much!
Hi Professor Kelly,
First let me compliment you on your series of videos on the Chevrolet Bolt. I have watched everyone and learned a lot. They are great because they make the complicated seem simple. That is a talent. Thank you.
I have also watched several of your videos on the Prius. Again you did an excellent job of making the sophisticated simple.
I have a request. Would you consider demonstrating, on a video, the installation of a 12 VDC to 120 VAC inverter into the Bolt? I believe in order to make this work as a backup emergency system the Bolt needs to be on?
Again thank you for very interesting, detailed and thorough videos.
Leo
With your deep insight into the vehicle do you feel there are areas that could potentially be susceptible to fire risk? I ask because one caught on fire close by yesterday and I am wondering if there are any additional precautions us Bolt owners can take to minimize potential fire risk. I have on video on my channel describing the one that caught fire yesterday if you are curious. Thank again for the information you have provided in your videos, it is greatly appreciated.
I admire your ability to work on these things. The more I watch your videos on the Bolt, the more I like it... The quality, logical design and easy of assembly of this car make me want this car more and more... I have a Nissan Leaf and it does not appear to be of such high quality..
Thank you and thanks for your feedback!
Thank you very much Professor, really enjoyed the training video, the quality audio and pristine video made for riveting viewing, once again a big thanks from Scotland cheers sandy
Thank you very much!
Fortunately in a collision, most of these systems are disabled automatically. However emergency personnel would be wise to understand basics. The first few steps are similar to our Lexus hybrid, with the same orange color for high voltage wires.
Great video. Provides a better understanding of how batteries are designed and work. Thank you.
Thank you and thanks for your feedback!
This is very nice to see you take apart the Bolt, I have a 2017 also and a 2017 Volt. It is nice to see how it works!
Thank you!
I'm thinking about getting a used Volt but the transmission is over complicated. It's a great idea, but have any common issues developed in the volt? I like the simplicity of an EV better but I can't afford a new Bolt
I have not heard of any common issues with the Volt transmissions. My 2014 Volt has 50k miles on it without any issues. My 2012 Volt was also trouble free. My co-worker bought a used 2012 Volt with 100k miles on it. It also has no issues. Best wishes.
Thank you Professor Kelly. We learn so much watching your videos.
You are welcome
I am EXTREMELY surprised that there is no protection plate under the volt for protection of the battery and all those hoses. Tesla learned that lesson and now every Tesla has a titanium cover underneath. Also helps with aerodynamics.
great video, audio and instructions. Your students and us proxy students on the internet are lucky
Thank you!
That is the professor to do the job. Very well done.
thank for sharing this video. seeing videos like this really shows that electric cars are coming of age.
Thank you!
Very nice, I always enjoy your organized approach. Look forward to seeing the insides.
Thank you!
ENCORE-----Please further instruct on how to install the battery, its connections , the lower cover and the operational checkout. GM needs to produce some service manual series and soon! THANKS.....
Thank you! All of those topics are coming in the next few weeks. Thanks for the feedback!
Definitely a complicated procedure that needs attention to detail. Thanks for sharing
Thank you!
Hey just found your channel. Top notch quality audio and visual and top info too. Thanks so much for doing these!
Thank you very much!
Mr. Kelly thank you for the video I always watch your videos they're very affirmative could you please tell me the scissor lift is it OTC please let me know cuz I'm going to purchase one for my shop thank you sir
Thanks once again for an excellent vid - look forward to the next part of the disassembly of the Bolt!
Thank you very much!
Did you happen to notice on the underside, there is approximately 80% of a spare tire well (don't believe this is capture? I'm still scratching my head on that one.
I believe with fast charging the power is transferred through the same large cables that connect the battery and controller(?). GM manufacturing Bolts w/out DCFC is unfortunate. I own a Spark EV w/ DCFC.
You do good work sir, thank you for sharing.
Thank you! I have not looked in the compartment on the car yet. It does look like a spare tire area, but it is probably just storage. I just verified it, you are absolutely correct. When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector is only used when using a Level 1 or Level 2 AC J-1772 charger connector. Thanks again, have a great day!
Although it looks like a spare tire well, one would definitely NOT fit. However, a factory wheel with a tire fits just about perfect under the false floor if you have the option or bought it aftermarket.
The well has a big foam block which provides storage for the recovery hook, the optional (?) air compressor, and 120 volt charging cord.
John, would you PLEASE make a UA-cam video explaining how to understand and charge The Chevy Bolt all 3 levels..
I've watched so many videos that are vague about how to plan a trip for charging.How much time it will take to charge. Even charging to 67 %, then moving on.
I'm so trying to learn how to know if a charger even works by the time you arrive to recharge on these long distant trips in the bolt EV. You explain things so well. So many people would benefit from your shared knowledge. Thank you,
Thank you for the video. I'm looking to buy one of these and expecting to have to change the battery in 10 years. Seems easy enough with the right tools.
We are glad you are feeling better from the flu. This Bolt EV video is great! :)
Thank you!
Just finished watching, now i can go to sleep!
Always a great pleasure to watch your beautifully made and professional lessons, I'm really looking forward to the next video!
Thank you very much!
Really it is very interesting course which video and audio quality which very clear and simple explication method I like it well. Good job professor and thank you very much. JLR technician from Morocco🙏🏻
Excellent presentation. Thank you very much. Looking forward to future videos in this series.
Thank you!
Boy if I ever get an electric car,I would sure like him to work on it. He's a great mechanic.i would trust him 100%
Dear Professor, I noticed you work alone most of the time. As a suggestion, for safety reasons, would be good for you to have some companion. Thanks for posting and share!
Very true! Thanks for your feedback!
Excellent video! So clear and easy to follow! Wish all instructional videos be like this! Thumbs up! Thx
Thank you!
I love the Chevy BOLT. If I was in the market for an electric car, this would be it! Cool Video.
Thank you!
parabéns pelo trabalho e pela autonomia da cadeira
Muito obrigado!
I’ve watched hours of your videos and 5:40 is the first time you’ve appeared upset. It’s alright to swear, Professor.....I do it all the time when trying to figure out what the holy hell so-called engineers were thinking. Thank you, and keep up the good work!
LOL, Thank you! I was swearing silently in my mind ;)
Dang, thats actually really easy to do provided you have something that can hold and move the battery. I can see doing it without a lift if you have some heavy jacks and a really well made cart.
Thank you so much for the great video. I am surprised the bolt has such a thin battery design comparing to BMW i3. I guess the reason behind is the drive train layout? So I guess the bolt is front wheel drive, which Chevy could fit the motor under the hood, and free up the space under rear seat for batteries and control module. And i3 is rear wheel drive, so the space under rear seat and trunk is taken out by the motor and optional generator, so the battery has to be a relatively flat module to fit under the floor, also it can't stick out too much in front in case of frontal collision, don't want to damage the batteries and control module. But still just look from the outside the LG cells in Chevy Bolts seems to be a lot shorter(thinner) than the Samsung cells in BMW i3
Thank you and thanks for he feedback! Teslas are RWD or AWD with a flat battery under the car as well.
But this is huge at the back. BMW pack weights half this one. Their 94Ah, 33kWh slightly more than the original.
Luke W I do like the Samsung cells on i3, already have 50k miles on it, estimate capacity lost is around 1%. But the range is kind of short, not very impressive
Guo Richard good to hear you are driving an i3. Yes 60ah without a heat pump isn't great especially as the cat isn't very aerodynamic. But it's fun to drive and you can swap to higher capacity battery pack easier than most.
Professor John Kelly. I’m fascinated about You explains Your dissecting the different cooling passages, different bearing types, grease, oils, antifreeze coolant. This unit was from a fire damaged 2026 MODEL S. You do a much more detailed explanation than Sandy Munro. I’m sure You would both have total respect for each other’s analysis. I would like to know how this motor evolved starting in 2012 with probably many prototypes with failures, and redesign and to a product that will last more than 20 years. My observations are how unique the requirements for sealing are which are much more complicated than any Gas Engine. The seals used and routing of coolant both internally and externally to
Continued. To Super bottle and then Octo Vakve. Many Questions: How many types of motors, drive trains, and did they élever have catastrophic failures on this developing process to engineering excellence. I’m waiting for CYBERTRUCK DUSL MOTOR. Thank You.
Thanks for the information
Hope you get to feeling better in the near future !!!
Thank you!
A well done video. Thank you. It's interesting to see the connectors, fitting and labels.
Thank you very much!
This guy's a stud, amazing tools, such a cool, clean shop, appreciate sharing and keep up the great work!
Thank you very much!
You're an inspiration. So intelligent and thorough videos keep up the great work and educate us on those wonderful electric cars. Thanks for training future technicians
Thank you very much!
Great detail as always, Professor Kelly!
Would you consider having the B(ravo)olt over your V(ictor)olt?? Assuming of course you still own Victor...
Also, there seems to be an awful lot of surface area with all the webbing in the under structure of this car. Could that present issues in the future with corrosion as I see lots of places for road salt, etc to live. I'm wondering what you think?
👋🏻
Thank you! I would like a Bolt. I would still keep my Volt. The lower tray is 0.050" (1.27mm) thick. The webbing is 0.094" (2.39mm thick). It is made to withstand running over objects without penetration. I think It will be okay. Thanks for your feedback.
sorry my mistake, you mentioned it later in the video. sorry. thanks again for the excellent videos.
Thank you very much!
Excellent video however I would be concerned about the car shifting or possibly falling off the lift due to front heavy weight distribution-perhaps strapping the rear of the car to the lift would solve this issue
Congratulations on your award, you deserve it, keep on truck-in!
Thank you!
real nice quality video. very professional and thorough.
Thank you very much! Have a good day!
Very well done. Your patience is remarkable. You explain technical aspects very well, a nice balance of clarifying concepts in some instances while seemingly having expectations that the listener is an educated layman that does not need handholding.
This topic is highly interesting to this retired white collar guy who likes getting hands dirty turning wrenches. Being convinced that EV is the solution to the near future, I dare say that very many find your topics of great value. You are trail blazing what I contend is one of the most important technical maintenance areas into the rest of the 21st century. Thanks, as well to Weber State for supporting you in bringing your channel to life!
Thank you very much!
Thank you Prof.Kelly !
Thank you!
Its master Yoda! Watching your work is awesome! Thanks!
Great educational video, thank you very much Professor!...Are you planning a deep dive on Tesla Model 3 HV battery/BDU?
Thank you. I would like to teardown a model 3, but it is unlikely we will see one very soon. Thanks for the feedback.
Great video as usual! Always enjoyable & a learning experience watching your videos!
Thank you very much!
thank uz georgia for a useful and informative lesson ser.
Thank you
Those meter leads are sick!
Thank you! They are nice
I was hoping you would pop the top and get a peek! I that battery pack serviceable? Can individual cells/packs be replaced?
Thanks for the video, interesting.
I will pop the top in the next video and totally disassemble the entire battery pack. Thanks for your feedback! Individual cells cannot be replaced. Only the battery modules.
Amazing Video. love how clearly you showed and detailed that for us. Great insight!
With the Big GM recall of those LG Chem batteries, its great to know what they will actually be doing to our cars.
Thank you!
Great video as always. Is the power steering rack electric or hydraulic? Thanks.
Lifting the last section high enough to look under, it is visible how inefficient the contact is with the thermal transfer pad! [assuming the darker color is the stain on the metal from the adhesive, and the lighter metal has not come in contact at all?]
It is difficult to tell for sure. I will see if I can do an experiment with contact marking dye to determine contact area. Thanks for your feedback!
Wow. Thanks for posting. I’m a Bolt Premier owner. So interesting to see what’s going on under the car.
Thank you
Looks like a fun job to do in the driveway using a floor jack and a 2x6.
I wonder how the bottom steel battery pack will hold up over time in northern states with road salt.
It appears to be made of a thick steel. I will measure it when I take the cover off this week. Thanks for your feedback!
Paul Wicklund that and all the salty slushy sandy snow in mn will wreek havoc on those connectors and such underneath unless there is some kind of shield covering them?
There is a large reinforced plastic cover under the vehicle. I neglected to show it in the video. Everything is well protected.
GM has an undercoating solution for the Bolt, and I imagine that, once out of warranty, you could get away with any non conductive corrosion resistant product like Rust Check or Corrosion Free. I know that some people think that undercoating is a "scam", but those of us who live in the rust belt know for a fact that even on new cars, it's 100% a yearly requirement.
I live in the mag chloride belt and after a day out in the slush I always stop at the nearby car wash for a drivethrough underside washout. Then the heated garage.
Thank You professor. Very informative. Good audio and video.
Absolutely amazing step by step learning video. Thank you for taking the time and consideration in putting this video together. Please keep up the great work.
Thank you for this fascinating video. I was wondering what the labor hours would be to have this done at a dealership? In some ways it seems easier than a normal engine removal, but more difficult in others. Will these cars see multiple owner paid for battery packs in respective their lifetimes, thus making them viable to operate economically well past the normal 150-250K mile service life we see today?
Thank you! Now that I see how easy it is to swap out the battery, I suspect it would take 2 hours labor for the complete job. I also suspect the batteries will last well beyond 100k miles. The rest of the Powertrain is pretty simple. Not much to go wrong mechanically.
WeberAuto yes, I think the batteries are reliable enough, I have a 2014 BMW i3 Rex, already put 50k miles on it, so far I have the exactly the same range as I bought it 3 years ago. And few days ago in the i3 FB group, someone actually just hit 100k miles on the original battery, and lost about 4% of the capacity.
This couple of years video is coming in handy with the Bolt EV recall of Friday November 13, nobody know at this point what is going to be the final solution to the “ battery fire”problem. But if it is a battery replacement at least we know what they will be doing and what is going to fail in the car next (probably the coolant pump seals, for not removing air) after the battery replacement is done. Not sure if the technicians at my Chevy dealer are going to be able to do this with the finest of the profesor.
amazing !!!!!!!!
what is the GM warranty TIME for removal ?
what is the Customer time for removal ?
Thank you! I do not know the warranty or customer labor time. I suspect is is somewhere in the 2 to 3 hour range.
GM Warranty time always CHEAP !!!
I worked on the 2004 Silverado MILD HYBRID - START STOP
only paid 4 hrs to replace the Burnt out Stator
Bad DESIGN , had lots of battery Codes
Did you ever figure out what the leak from the steering gear was? My Bolt has a binding steering gear and my friend and I have been arguing about how the rack might have failed, and I remember you spotted a leak near your steering gear. Did you ever diagnose it? GM would claim it's wax in this TSB - 16-NA-109. But it seems counter intuitive that the steering gear would use oil vs grease.
I sold my first Bolt to my brother in NC…..it is scheduled to get her battery replace on 12/31. He was told it would take 4.5 hours.
Keeping lithium ion batterys 30-80% charged greatly extends their useful life. This is the long life trick for your smartphone (charge for 30min at a time), tablet, laptop, smartwatch etc!
Regular 100% charging of lithium ion batteries causes shrink swell damage to the cathode (lithium cobalt) and anode (hard carbon) ; causing a progressive accelerated loss of capacity
Any thoughts about the charge controller & BMS in hybrid & electric vehicles protecting the large expensive batteries from overcharge damage ? Toyota already proved that 20-90% charging greatly enhances the battery lifetime of NiMH and Lithium Ion batteries in their hybrid vehicles!
Thanks for your feedback!
Your a very polite & responsive channel moderator. Thank you for always giving kind responses. I would be honored to meet you & visit the facility where you have all these cool hybrid & electric vehicles being taken apart & put back together! Super cool! Thank you for posting these edifying interesting well made videos! Cheers
Thankfully, the Bolt has a feature to extend the life of the battery. In the Energy Section of the radio, go into the menu and enable Hilltop Reserve if you can spare about 20 miles of range. This will change the "Full charge" from 100% to 90%. The true purpose of this feature is to enable extra regen capacity for those that live on top of a hill, but it works great for extending the life of the battery when you don't need a completely full charge. It's even location-based if you want so that the Bolt will fully charge if you charge away from a certain location or only at a certain location.
I understand newer Bolts allow more control of the full charge cutoff point, similar to how Tesla accomplishes this.
Nice to see, as basically 150,000 Bolts will be going through this battery pull out.
Than you so much! Awesome video can’t wait for the next one when you open it. Would be cool to make it a PowerWall 😂
Thank you!
You have my respect professor....
Thank you!
I WANT TO say thanks for this video .we wait another beautiful video B.J
Thank you!
Thank you, Professor. You mentioned there are two battery designs and that this Bolt does not have the fast DC charging option. I don’t see a fast charge connector on this pack. 1st Q: Do you know if the other pack design is for the fast DC charging or why there would be two pack designs for this vehicle? 2nd Q: Where are you getting your service information from? Do you have a subscription or were you able to purchase a service manual? I was hoping to obtain a service manual for the Bolt, myself.
Thank you! Correction to my video: When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector shown in the video is only used when using a Level 1 or Level 2 AC J-1772 charger connector.
I am getting the battery pack design information from the Chevrolet Service information. It shows the New Design Battery Pack being installed in Vehicles built after 1G1FX6S06H4163254. The first design battery has two female coolant connections at the battery. The first design also has the service disconnect lever (under the back seat) as opening from the driver's side of the vehicle rather than opening from the passenger side of the vehicle.
The EPA Service information act of 1995 requires that all factory service information be made available online. You can see all of the service information prices and links here www.nastf.org/i4a/pages/index.cfm?pageid=3291 Paper service manuals are no longer available. Best wishes!
I was wrong in my previous comment to you. I have edited it to be correct. When using the DC fast charger, the large 2 wire connector at the battery is used. The small 2 wire connector is only used when using a Level 1 or Level 2 AC J-1772 charger connector.
WeberAuto Thanks, again. The second design must have been some poke-yoke-ing to eliminate goofs at the manufacturing plant as the differing ports prevent mis-assembly. I can only surmise that the reversal of the service disconnect was for another optimization improvement. Thank you for the service link. It seems all automakers have gone this route. Pricey for the garage mechanic (I still like to do my own brakes, you know!).
Great work. I think you answered every question!
you get all the cool equipment. good video.
Thanks, it is a lot of fun for me!
Great video.
By the way what are the dimensions of the battery pack?
Thanks for an informative video. Have you done a BMW i3 60Ah or 94Ah pack?
Thank you, no, not yet. Thanks for your feedback
So a battery swap and software update should take at most 4 hours?
Yes, assuming all the tools and equipment are functioning and ready to use.
Beautiful video Professor, blessing from Jamaica.
Thank you!
Hello, I have some detailed questions: When should we add oil to the engine? For example, I added oil 1 year ago and it still shows 90%, should I change the oil in this case? , also, when is it better to charge the battery, should it sit until the end and then charge? If, for example, the battery shows 50%, 60% or something else, then can it be charged? Which is better for battery care? And another question, how many amperes is better to charge the car?
Excellent videos !!! Very good!!! Thank you. My regards from Uruguay !!!
Speaking of the 12 volt battery: is it a "standard" lead acid type? I've long wondered why, with hybrids and election seeming to be the greatest thing since sliced bread "they" don't save some weight and gain some capacity by replacing the lead cell with a Li cell in even the most "conventional" automobile.
It is a special kind of lead-acid battery, an Absorbant Glass Mat (AGM) battery. They have very high energy density for their size compared to other battery types, but they are also very heavy.
Cost, I think. It does seem a bit odd as a lithium pack of the same capacity would be about 1/3rd the weight, and weight matters on EVs. But it would cost at least 3 times as much and so far no-one seems to have gone for this. It's also true that all the standard 12V parts are designed for lead-acid voltages so it's just easy. You really need to use 4x3.3V LFP cells to get a more-or-less equivalent LA/AGM voltage, as opposed to the more typical 3.6V (3.0-4.1V) of most lithium chemistries (4x3.6V (14.4V) is a bit high, and 4*4.1V (16.4V) charge voltage is definitely too high. )
My Spark EV has a lead acid 12v too. Scratching my head about the use of the old tech lead acid , price has to be the reason .
I may have missed it, but were the dimensions of the pack provided in the video? Specifically length/width? Thanks! :) (Love the vids!)