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Chevrolet

Bolt EV (2022-2023)

BEV · Battery Electric350V system
1

Wait

minute

after 12V cut before HV contact

Do not touch HV components until wait time has passed

FRONT

12V

MID

HV pack

REAR

MSD
HV pack zone12V batteryHV disable loop / service plug
  • MSD — Manual Service Disconnect — under the rear seat cushion (interior access, 2022-2023 ERG)

Schematic zones only — front/mid/rear are approximate. Verify exact locations against the OEM Emergency Response Guide.

First 10 minutes — pre-flight

Before you touch the vehicle. Run this once for every inbound EV or hybrid.

  1. Park downwind, on level ground

    If the pack is in thermal runaway it will vent flammable + toxic gas. Stay upwind. Block wheels.

  2. PPE on: HV-rated gloves, safety glasses, no jewelry

    Class 0 (1000V) rubber insulating gloves with leather over-protectors are the floor for any HV work.

  3. Walk-around: damage scan + signs of pack compromise

    Coolant pooling, white smoke/vapor, hissing, bulging panels, exposed orange cables, or chemical smell = stop. Treat as live and call OEM hotline.

  4. Confirm the vehicle is this card (year, make, model)

    Pack location and disable procedure differ between generations. Use the distinguishing visual to be sure.

  5. Locate your fire suppression and first-aid kit before starting

    Water is the only effective agent on Li-ion. Dry chemical, foam, and CO₂ will not stop a runaway. Have ≥250 gallons accessible.

HV Disable

  1. Primary
    Turn ignition OFF, remove keys, then DOUBLE-CUT all low-voltage cables marked with yellow tape above the 12V battery

    Under hood, left (driver) side of forward compartment, directly above the 12V battery — yellow-tape-marked low-voltage cables

  2. Backup
    Manual Service Disconnect (MSD) — "High Voltage Battery Manual Disconnect Lever" — lift rear seat cushion (release 2 clips), lift connector position assurance retainer, push lever button, rotate lever, remove assembly. Documented in GM 2022-2023 ERG.

    Under the rear seat cushion (interior cabin access). NOT accessed from the underbody.

Note
DO NOT cut any orange-jacketed high-voltage cables. The yellow-tape low-voltage cables sever the HV contactor coil circuit, opening the contactors and isolating the pack. Cutting orange cables is hazardous and not the disable method.

12V battery & SRS

12V location: Under hood, left (driver) side of forward compartment — the yellow-tape low-voltage cables are routed directly above this battery

Disconnecting / cutting the marked low-voltage cables above the 12V battery is the OFFICIAL GM disable procedure. This both isolates the HV pack and removes 12V power. After cut, wait at least 10 seconds before SRS-area work.

discharge: wait 10s after airbag deployment before touching SRS components.

Pack & no-cut zones

Pack location: Floor-mounted underbody (full footprint beneath passenger cabin; "T"-shape extends under rear seat)

Pack chemistry: Lithium-ion (LG Chem nickel-rich pouch cells)

cable color:Orange

Do not cut:

  • Orange-jacketed HV cables (entire routing — under-floor and engine bay)
  • HV battery pack footprint (entire passenger-compartment floor pan; "T"-extension under rear seat)
  • SRS components (steering column, B-pillars, roof rails, seat-mounted side airbags)
  • Stored-gas inflators (airbag canisters)
  • Gas struts / preloaded springs (liftgate, hood)
  • Seat-belt pretensioners (B-pillar lower)

Reinforcement (UHSS):

  • A-pillars
  • B-pillars
  • Roof rails
  • Rocker panels (battery pack perimeter)
  • Front and rear bumper beams

Pack piercing risk: Pack tray is the lowest structural element. Any underbody tool, fork-truck tine, or jack stand that contacts the pack from below risks piercing the case and triggering thermal runaway. Treat every Bolt EV as a potential 2017-2022 RECALL vehicle — LG Chem cell defects can cause SPONTANEOUS internal short and fire even without external damage. (NHTSA recall 21V-650.)

Isolate damaged vehicle 50 ft from exposures.

Open NHTSA recalls (7)

Live from NHTSA. Cross-check the VIN against nhtsa.gov/recalls before work.

⚠ Critical advisories (3) — NHTSA Park-It or Park-Outside

  • PARK OUTSIDE

    24V812000 · MY 2022 · ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY

    General Motors, LLC (GM) is recalling certain 2020-2022 Chevrolet Bolt EV and 2022 Bolt EUV vehicles previously repaired under Recall 21V-650. The installation of advanced diagnostic software may have failed. As such, the high voltage battery could catch fire when charged to full or nearly full capacity.

    Remedy: Owners are advised to take the following interim steps: Set the Target Charge Level feature in their vehicle to limit the charge level to 90%, charge their vehicle more frequently, avoid depleting the battery to 70 miles range remaining, park outside after charging, and do not charge the vehicle indoors overnight. Dealers will reinstall advanced diagnostic software, free of charge. Owner notification letters were mailed December 3, 2024. Owners may contact the Bolt EV Concierge Team at 1-833-382-4389. GM's number for this recall is N242470160.

    Filed

Responder-relevant (2)

  • 23V845000 · MY 2022 · STRUCTURE:BODY:ROOF AND PILLARS

    General Motors, LLC (GM) is recalling certain 2017-2023 Chevrolet Bolt EV vehicles. This recall includes certain vehicles previously repaired incorrectly under NHTSA recall number 22V-930. After a crash with seat belt pretensioner deployment, the pretensioner exhaust may ignite carpet fibers near the B-pillar, causing a fire.

    Remedy: Dealers will inspect both front seat belt pretensioners and, if necessary, install metal foil at the carpet near the pretensioner exhaust. Certain vehicles will also need a pretensioner cover installed. Repairs will be performed free of charge. Owner notification letters were mailed January 24, 2024. These vehicles were previously recalled for this same issue under recall number 22V-930 and will need to have the new remedy performed. Owners may contact GM EV Concierge at 1-833-EVCHEVY (1-833-382-4389) (TTY 711 / 1-800-833-2438) or Customer Service at 1-800-222-1020. GM's number for this recall is N232421970.

    Filed

  • 22V930000 · MY 2022 · STRUCTURE:BODY:ROOF AND PILLARS

    General Motors, LLC (GM) is recalling certain 2017-2023 Chevrolet Bolt EV vehicles. After a crash with seat belt pretensioner deployment, the pretensioner exhaust may ignite carpet fibers near the B-pillar, causing a fire.

    Remedy: Dealers will install metal foil at the carpet near the pretensioner exhaust, and install a pretensioner cover as necessary, free of charge. Owner notification letters were mailed between January 23, 2023 and April 25, 2023. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is N222383790.

    Filed

Show 2 other recalls
  • 23V567000 · MY 2022 · AIR BAGS:FRONTAL

    General Motors, LLC (GM) is recalling certain 2022-2023 Chevrolet Bolt EV vehicles. The instrument panel may be missing the perforation on the underside of the panel cover that allows the passenger-s…

  • 21V517000 · MY 2022 · AIR BAGS:FRONTAL

    General Motors, LLC. (GM) is recalling certain 2022 Chevrolet Bolt EV and Bolt EUV vehicles. One of the two fasteners that secure the driver's frontal air bag to the steering wheel may be missing or …

Lift / jack points

Use OEM-designated rocker lift points only. The battery pack occupies the entire underbody — do NOT lift on the pack case or pierce the pack tray.

Fluid hazards

Coolant: Glycol-based liquid coolant

Electrolyte color: Clear to pale yellow (vents as vapor when cells overheat)

If burning, toxic vapors:

  • Hydrogen fluoride (HF)
  • Carbon monoxide
  • Volatile organic compounds (electrolyte solvents)
  • Nickel / cobalt / manganese / lithium / copper / aluminum oxides

Firefighting

Show firefighting details — Water (copious / large volume) — per GM QRG, ~10,000 gal

Agent: Water (copious / large volume) — per GM QRG

Estimated volume: 10,000 gal

Reignition risk: 24 hours post-fire

Thermal imaging: required during monitoring

Source

Chevrolet Bolt EV Emergency Response Guide (PDF) →

Last verified · mirror

Confirm this is your vehicle

Show distinguishing visual

Tall 5-door subcompact hatchback; thin LED running lights flanking blacked-out grille; pronounced beltline kink at rear quarter window; "BOLT EV" badging on liftgate

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