Watch Chevy Bolt Battery Reassembly Process – 2-Hour Video


We’ve already witnessed the disassembly process for the Chevy Bolt battery. Now, it’s time to see how it all gets put back together.

Once again Weber Auto has released an incredibly comprehensive and informative video featuring a major component of a current electric car.

More From Weber Auto – Disassembly And Breakdown Of Toyota Prius Battery

This time around we’re seeing 2 hours worth of video focused on reassembly of the Chevy Bolt battery.

Video description:

Butter your popcorn and get ready for the first YouTube video showing the reassembly of a 2017 Chevrolet Bolt EV Battery!

Video Timeline:

Video introduction at 0:11
Battery tray at 0:57
MUST SEE: Battery tray weight at 1:38
Battery tray inspection plug at 2:35
Battery center of gravity mark at 3:20
The red shop stools at 4:20
The cooling plates at 5:39
The bus bars, BECM, low and high voltage harnesses at 6:43
Battery disconnect relay assembly at 7:23
Battery sections at 8:20
Reassembly procedures
Insulation pads at 9:35
Lower cooling plate at 10:30
Thermal pads at 11:18
Battery tubes at 19:48
X3 connector housing at 20:47
Cooling manifolds at 21:16
Battery Section Details
Safety zone at 22:38
Don’t freak out! 40 Volts will not hurt you at 23:00
Battery section 1 at 24:00
Battery module 1 with cell groups 1-10 at 25:27
Battery module 10 with cell groups 87-96 at 26:35
How the battery modules are connected together at 26:56
Battery section 5, module 5, details at 28:57
What is a cell group? at 31:36
How the Battery Energy Control Module (BECM) monitors cell voltages at 32:24
Special tool to measure cell voltages at 32:42
MUST SEE: Battery section 5, module 5, side cover removal at 33:37
MUST SEE: Closeup views of a cell group connections at 34:45
Cell group direct voltage measurement at 35:21
How cell groups are electrically connected at 35:40
Cell group voltage measurement with special tool at 36:56
MUST SEE: Can you take the battery module further apart? at 38:50
Installing battery section 1 at 41:24
Installing battery section 2 at 44:23
Installing battery section 3 at 45:25
Installing battery section 4 at 46:34
Attaching the battery sections to the battery tray 48:06
Battery section 4 voltage cell sensing harnesses at 50:23
Battery section 5 lower support brackets at 51:37
Battery section 5 insulation pad at 53:20
Battery section 5 cooling plate and hose clamps at 53:36
Battery section 5 at 54:54
Battery section 5 upper support brackets at 57:53
Time for Personal Protective Equipment (PPE) at 59:30
MUST SEE: Installation of high voltage bus bars at 1:00:17
Overall battery negative and positive terminals at 1:03:36
Low voltage wiring harness and temperature sensors at 1:04:57
Interlock circuit at the service disconnect lever connector at 1:07:00
High voltage cell voltage sensing harnesses at 1:08:18
MUST SEE: BECM details at 1:09:34
MUST SEE: BECM installation at 1:13:05
MUST SEE: Battery relay assembly components and operation at 1:20:01
MUST SEE: Battery relay assembly operation at 1:33:24
Cooling system leak check at 1:38:26
Installation of battery relay assembly at 1:40:52
X3 Connector installation at 1:44:23
X4 Charge connector installation at 1:44:57
MUST SEE: Battery system overview at 1:47:12

Weber Auto adds a few additional notes:

2017 Chevrolet Bolt EV 350.4V Li-Ion Battery Reassembly – A Youtube first!

Weber State University (WSU) – Department of Automotive Technology – Ardell Brown Technology Wing – Transmission Lab.

This is the third is a series of videos on the Chevrolet Bolt EV. This episode covers the reassembly of the 57kWh 350.4 volt 162.7 Ah battery from a 2017 Chevrolet Bolt EV. The components shown and operation will be similar to many other electric vehicles.

Yes, that’s 57 kWH, not 60 kWh as Chevrolet claims.

Categories: Battery Tech, Chevrolet, Videos


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33 Comments on "Watch Chevy Bolt Battery Reassembly Process – 2-Hour Video"

newest oldest most voted

It’s funny the way GM is talking about the Bolt and evs in general.
On the one hand they say they will increase Bolt production, but actual production is falling. Oh, wait, that’s this Summer that they will increase production, unlike last Summer when they shut production down for 3 weeks.
They are all-in on evs, as they are the future, but they want CAFE standards lowered. Well that’s a bit of disconnect. The point is just don’t believe anything they say.
Just like Musk if you say he’s lying but GM is telling the truth, then that’s a lie.


Reuters on July, 2017 “A spokesman for the company said the shutdown at Orion was “due solely to softening sales of the Sonic” model, adding that its production plan for the Bolt for this year was unchanged.”

Actual Evidence:
2017 Q1 Bolt EV Sales: 7,292 (before retooling)
2017 Q2 Bolt EV Sales: 16,005 (after retooling)1
2017 Production Increase after shutting down plant: +119%

YOY Increase:
Jan + Feb 2017: 2114
Jan + Feb 2018: 2601
Q1 YOY Production Increase So Far: 23% (Will be higher for the full quarter. Inventory was very limited in January. March YOY sales increase might be 2-fold if sales continue as they have the first half of the month.)

As far as CAFE goes, I have heard nothing to imply that GM is pushing for lowered standards, but updated/modernized ones.

Barra and other spokespersons have said specifically that they want CAFE to include a reflection to the change over to EVs, AVs and ride sharing. They have said they want California to be involved in the negotiation process. Doing so would potentially make it more CARB like. Since GM has moved to increase EVs rather than hybrids, they’re probably better prepared to meet CARB standards than CAFE.


The TSLA fanbois don’t like the truth. ffbj won’t be seen commenting in this post again after being so thoroughly owned by you. 🙂


Don’t be so silly. Wasn’t he the pone that said the Bolt would surpass the Model 3 the first quarter, which was just brilliant analysis and completely wrong, which he usually is.
You are such a FM shill, that you really have no credibility whatsoever when it comes to what you have to say about them. It’s just company line.


Who, me? No. I literally *never* said that. Please show me where you think I said that.

I guessed that Bolt would lead in January and that both cars would hit between 1500 and 2000 sales. But I overestimated 2018 Bolt deliveries for the month since almost all inventory was 2017s.

In fact you can see me on the record at the end of January that by March the Model 3 would already have a healthy lead. That is the exact opposite of saying that Bolt would outsell the Model 3 in Q1.

And when the Model 3 did outsell the Bolt, I said “Yeah, Bolt sales were way lower than I expected! Model 3 sales were exactly where I expected. So good for Tesla! 🙂 In that case the Model 3 will probably lead for all 12 months of this year!”


“Wasn’t he the pone that said the Bolt would surpass the Model 3 the first quarter, which was just brilliant analysis and completely wrong, which he usually is.”

You must be talking about some other WadeTyhon. 😉 The one who posts over on the InsideEVs forum is clearly one of the better-informed Usual Suspects, especially on the subjects of automotive production and marketing. I won’t say he’s never wrong, but he has impressed me with the depth and breadth of his knowledge of this subject. I won’t say he’s never wrong, but I don’t recall ever reading a post from him which contained anything which wasn’t true.

If you are tempted to argue with WadeTyhon, then I strongly suggest you check your facts first.


Well thank you but of course I’m wrong sometimes! 😛

Of course I try to let the facts form my opinions, so new information might change my outlook on something. I try to make it clear when I’m speculating on a topic rather than stating definitive facts.

It’s easier when the primary goal is to support EVs not simply ‘Support GM’ or ‘Support Tesla’ or what have you!


*Meant to say H1 and H1 not Q1 and Q2


You know nothing.


I know nothing? I am providing you with actual hard evidence because I’m trying to be informative not combative.

Production and sales doubled in the 2nd half of last year. Production is up YOY this year as well and will rise further in March. It’s pretty crystal clear. Yet you’re claiming sales are down. What, because January and February sales aren’t as high as November and December? Of course they aren’t. That happens every year to literally every EV.

I’m just trying to provide information. If you have a good counterargument or reliable source that contradicts this, I want to know.

Despite what bro1999 might say, I’m not trying to make sure you are “thoroughly owned”.

You and bro should both stop trying to troll and spread FUD about the two companies that are making the biggest difference and are getting things moving on the EV front here in the US! 🙂


“Just like Musk if you say he’s lying but GM is telling the truth, then that’s a lie”

You may think Musk is a liar but I don’t.

He may be overly optimistic and ambitious. But eventually Tesla meets their goals. I’m confident the Model 3 will be a success.

Get Real

Can’t wait for Mental MadBro to rush in to defend his GM against that cogent analysis of GM’s cognitive dissonance on EVs.


Do you ever make a comment that doesn’t reference me like a cyberstalker? Get some professional help, child. It’s pretty sad.


That might be better coming from someone who isn’t so obsessed with trying to tear down Tesla’s good name that, almost daily, he posts Tesla Hater cultist comments even in response to articles having nothing whatsoever to do with Tesla Inc.


It’s hilarious because by their conferences they say this stuff, and then commenters try to defend which is just rich.
I did not know they said that.

We will increase the production if demand increases and we get the extension on the tax credits.
We are totally committed to evs but only if we get what we want. It’s just stupid.


Seriously, an article about Bolt EV packs assembly somehow triggers two “GM bashing” comments out of nowhere.

Of course, the two people that made the comment are the usual GM basher here. But seriously, do we really need to rant about something that has NOTHING to do with the article at home and go off on hating rant just because GM product is mention here?

Some people really have nothing else to do…


Adult children living in their parent’s basement don’t have much else to do, I guess. Sad.

(⌐■_■) Trollnonymous

….and eating Cheto’s with chopstix.


ModernMarvelFan complained:

“But seriously, do we really need to rant about something that has NOTHING to do with the article at home and go off on hating rant just because GM product is mention here?”

I’m going to archive MMF’s comment here, and quote that next time he does exactly what he’s complaining about here, with regards to Tesla instead of GM.

I shouldn’t have to wait long!


My complain is always on topic or related to the article coverage. If it is about battery assembly, then it will be about battery from that company. I don’t make generic complain about a company just because it is the maker of the product.

If they had talking about Bolt battery or its issues/design, I wouldn’t have any issues with. But as we both know that ffbj and get real are the two frequent GM bashers who just like to post bashing comments regardless of whether they are on topic or not.

you, on the other hand, often can’t stop yourself from insulting people first and then start talking about comments later.

The fact that you jump into this thread just shows that your bias in attempting to attack me about their obvious bias. Seriously, get a life too.

And this article HAS ZERO MENTIONING OF Tesla, yet, you have to make a mention of it.


Unfortunately, you are talking to a brick wall.


Yep, that is one point lost on these Elon fluffers. I have no problem admitting I am very critical of Tesla, but at least I keep the criticism on topic.
Oh, there’s an article about terrible Tesla build quality? I’ll comment about that terrible build quality. An IEVs sales scorecard article, and a bunch of buffoon TSLA fanbois are crowing about how the Model 3 was #1 in sales that month (and usually slamming GM at the same time)? I have no problem bringing up the continued busted production benchmarks of Elon, and how they are ludicrously off their even revised production goals.

But here you have Beavis (ffbj) and Butthead (Get FUD) here commenting on an article about the Bolt’s battery that doesn’t even hint at a reference to Tesla, yet they feel the need to bash GM and post totally irrelevant nonsense intent PURELY on looking for a fight.
I mean look at Get FUD’s first post. If that is not trolling, I don’t know what is. I seriously hope that guy gets some mental help, because he has problems.


Props to the professor for posting these awesome vids! Info overload for even a fan like myself, but cool to see the Bolt’s battery up close like that.


One interesting part is that battery balancing board say “Volt” on it. So GM is obviously leveraging design/parts across its PEVs.

I guess it sort refutes some of early complains from some Bolt bashers that Volt is a PHEV so GM got nothing to leverage on for Bolt. I guess that is easily proven false.


re: Bolt production: I predict that GM will either be making an MSRP price drop or increase dealer discounts soon. They wouldn’t announce production increases unless they believed the market would buy them and they’ve got a feel now for what the market sweet spot is.


re: assembly video. My first thought is – the Bolt modules are well-engineered to be very easy to assemble via automated process. The cell groups all just stack together with insulating separators + aluminum heat plates and then just two long bolts pull them together. Drop the modules on a single big cooling plate and connect up all the buss bars and control sensor plugs and away you go.

LG could be banging out 1000’s of these packs per week without “production hell” or emergency man-years of software revisions and complete bandolier and module assembly automated equipment replacements from Germany.

George Bower


Hah. Just watched the whole thing. Learned a lot. Thx IEV’s for posting it. Could very well end up with some interesting comparisons with the Jaguar battery and the Tesla battery.

John Doe

Interesting video.

When you look at the battery disconnect unit, I wonder if manufacturers will make these a lot more integrated, or even fully integrated as one single unit – as EV volumes get higher.
Simpler, cheaper and smaller.
Just integrate all in a battery control unit, that also has the disconnect unit integrated. Not just a lot of modules, integrated in another unit like it is now.

Also, the cooling pads, I would think a thermal compound would do the same job. Just like they use in power modules and some transformers – or under CPU coolers, cooling elements, and stuff like that.

I think that from one generation to another, there must be ways to make a battery pack cheaper, and faster to take a part and change cells/battery units. Make it more integrated, better harnesses that include all in one (power and signaling).

I think be does a fantastic job with the videos. Very educational, lots of details.


The cooling pads are a lot easier to put down than some type of paste. It’s also easier to deal with if you have to do repairs.

John Doe

I used to work at a company that made transformers, and control electronics.
We used thermal paste, and it came in 10 liter buckets. It was added with a tool very similar to what you use when laying tiles.
It could easyly be removed too, by just scraping it up.

For smaller units that was assembles by a robot, it used an automatic dispencer that did the job too.
I guess that would be the option used in the auto industry (due to volume production).
Just like the auto industry use to apply glue or sealer material.


One thing I found is that how short the cells are. The series configuration also allow the module to be extremely modular and can be swapped out easily.

Bill Howland

IEV’s and this guy (who does an excellent job explaining), insist on calling this a ’57 kwh’ battery , due to the conservative legally required 95% Dept of Energy rating.

The rest of us can confidently call it a 60.0 kwh battery since hopefully the requisite degredation down to 95% is years away.


Very interesting video. You always talk about cooling plates. Are they are also used to heat up the cells as the cells can not be charged very well in low temperature conditions?
If so, do you know how and how much heat power can be brought into the battery?
Question is since the Bolt uses the same cells as the Renault Zoe in Europe which also shares the same problems of charging.