Grab your popcorn and get ready for all the boring technical details you have been craving!

TIMELINE
0:00 *Introduction
3:25 Under-vehicle view with battery installed
5:42 Battery removal
7:05 Under-vehicle view with the battery removed
11:15 Exposed battery "roll-around"
12:06 Battery tray
12:30 Battery tray inspection plug
14:26 High Voltage safety warning
15:32 Battery sections
16:00 Battery modules and power ratings
16:38 Battery cell groups
19:20 Battery configuration summary
20:50 Cell group identification/numbering
22:50 MUST SEE - Cell group demonstration
23:30 MUST SEE - Parallel cell group individual Li-Lon cell
24:35 **(See note below) Cell group Ah rating versus cell group Wh rating error I made
24:45 MUST SEE - Cell group cooling and cooling plate
29:35 Battery section 3 installation with lifting adapter (first attempt)
30:50 Personal Protective Equipment (PPE) usage
31:10 Battery section 3 installation with lifting adapter
40:20 Battery cell group electrical configuration
42:50 MUST SEE - Parallel cell groups and bus bars
44:30 Overall battery negative terminal
45:10 Cell group voltage sensing lines
46:25 Battery cell group voltages
49:15 0.3V Cell ground voltage differential and cell balancing
50:00 Battery cell voltage testing tool
57:00 Battery section 2 installation
58:10 Battery section 1 installation
59:15 Coolant hose connections
1:05:17 Battery cable harnesses
1:06:55 Battery section temperature sensors
1:08:55 Installation of battery negative cable
1:12:25 Installation of battery positive cable and series cables
1:15:53 Battery service disconnect plug discussion and safety demonstration
1:18:45 Installation of voltage sensing and temperature sensor harness
1:22:22 Battery Energy Control Module (BECM) installation
1.25.00 Battery relay assembly components
1.25.27 Battery relay assembly electrical connections
1:31:40 Battery coolant heater (1.75 kW)
1:34:35 Coolant manifold fittings
1:41:15 HV current sensor (fine and coarse resolutions)
1:42:50 Positive contactor
1.43.30 Negative contactor
1:43:40 Coolant heater transistor module
1:44:10 Plug-in Charger contactor
1:44:50 Coolant heater 450V 10A fuse
1:45:20 Pre-charge resistor
1.45.35 Pre-charge contactor
1:46:50 Battery relay assembly low voltage ground circuits
1:47:35 Coolant hoses
1:50:18 High Voltage fuses and cover with interlock
1:51:54 Battery service disconnect plug components
1:52:15 Service plug high voltage interlock circuit
1.52.55 420V 350 amp fuse
1:54:34 Service disconnect plug positions for removal
1:56:54 Installation of battery relay assembly on the battery tray
2.01.40 Overall review and battery "roll-around"

*Series Hybrid Clarification:
The 1st generation Volt is a series hybrid in 3 out of 4 modes of operation of the 4ET50 transaxle. The fourth mode (Electric Only Combined Engine On) is a series-parallel mode.
The 2nd generation Volt's 5ET50 transaxle has 5 modes of operation. Two modes are electric only, one mode is a series-hybrid mode, and the Two remaining modes (series-parallel) allow the ICE to contribute torque to the wheels through the planet carrier of the input gear set. This transaxle is used in a Malibu Hybrid with only 4 modes (they removed the series mode).

**1st generation Volt battery. If an individual cell is rated at 55.5Wh (using units of measure) Power (Wh) = EMF (V) x Current (A), then the current rating would be Wh/V = Ah. So 55.5Wh/3.7V = 15 Ah rather than the 55.5 Ah I mistakenly said/displayed in the video.

This is the first is a series of videos on the 2 generations of the Chevrolet Volt. This episode covers the removal and detailed reassembly of the 355.2-Volt battery and battery relay assembly from a 2018 Chevrolet Volt. The 2016-2018 Chevrolet Volt batteries are the same. The 2011-2015 Chevrolet Volt battery is similar but has some minor differences.

ABOUT US
Weber State University (WSU) Davis Campus - Automotive Technology Department - Advanced Vehicles Lab. We teach current vehicle technologies to our automotive students at Weber State University and online. For more information visit: http://www.weber.edu/automotive

This video was created and edited by Professor John D. Kelly at WSU. For a full biography, see http://www.weber.edu/automotive/J_Kel...

ADDITIONAL TRAINING FOR YOU
Join us for hybrid and electric vehicle training with two online courses and in a 5-day on-campus boot camp with Professor John D. Kelly. See http://www.weber.edu/evtraining

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