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2015 Chevy Spark will have lighter, smaller battery

As General Motors gets ready to release the 2015 Chevy Spark EV, it is retooling the Brownstown Battery Assembly to build a new battery system for the chirpy little electric car. The new Spark will lose a few pounds and kWh from its lithium-ion pack, but it will keep all of it's performance specs. The current Spark EV uses a 21-kWh lithium-ion battery pack with bits made by A123 Systems (known as B456 Systems during bankruptcy). For the 2015 model, GM is going to build a 19-kWh battery system in-house that will use 192 LG Chem cells. Losing a bit of energy capacity means that the battery system for the 2015 Spark EV will be 86 pounds lighter but it will keep the EPA-rated 82-mile range and 119 MPGe. The 2015 Spark EV also keeps its $26,685 (plus destination) starting price from the 2014 model. The car will once again qualify for a federal tax credit of up to $7,500. LG Chem also supplies the cells for GM's other plug-in vehicles from its facility in Western Michigan. The Brownstown production line currently builds the battery packs for the Chevy Volt, the Opel Ampera and the Cadillac ELR. You can read our first drive of the 2014 Chevy Spark here. Brownstown Battery Assembly Expands Capabilities Will build battery system for 2015 Chevrolet Spark EV 2014-05-14 DETROIT – General Motors will bring all its electric vehicle battery building capabilities in-house with production of battery systems for the 2015 Chevrolet Spark EV at its battery assembly plant in Brownstown, Mich. "Using our in-house engineering and manufacturing expertise enabled us to deliver a battery system that is more efficient and lighter than the 2014 Spark EV without sacrificing range," said Larry Nitz, executive director of GM global transmission and electrification engineering. "Our successful working relationship with LG Chem has allowed us to deliver a new battery system for the Spark EV that helps us to better leverage our economies of scale." A newly designed battery system features an overall storage capacity of 19 kWh and uses 192 lithium ion cells. The cells are produced at LG Chem's plant in Holland, Mich. The battery system weight of 474 lbs. is 86 pounds lighter than the system in the 2014 Spark EV. The Spark EV battery is built on a dedicated production line at Brownstown, which also manufactures complete battery packs for the Chevrolet Volt, Opel Ampera and Cadillac ELR.

GM won't really kill off the Chevy Volt and Cadillac CT6, will it?

General Motors is apparently considering killing off six slow-selling models by 2020, according to Reuters. But is that really likely? The news is mentioned in a story where UAW president Dennis Williams notes that slumping US car sales could threaten jobs at low-volume factories. Still, we're skeptical that GM is really serious about killing those cars. Reuters specifically calls out the Buick LaCrosse, Cadillac CT6, Cadillac XTS, Chevrolet Impala, Chevrolet Sonic, and the Chevrolet Volt. Most of these have been redesigned or refreshed within the past few model years. Four - the LaCrosse, Impala, CT6, and Volt - are built in the Hamtramck factory in Detroit. That plant has made only 35,000 cars this year - down 32 percent from 2016. A typical GM plant builds 200,000-300,000 vehicles a year. Of all the cars Williams listed, killing the XTS, Impala, and Sonic make the most sense. They're older and don't sell particularly well. On the other hand, axing the other three seems like an odd move. It would leave Buick and Cadillac without flagship sedans, at least until the rumored Cadillac CT8 arrives. The CT6 was a big investment for GM and backing out after just a few years would be a huge loss. It also uses GM's latest and best materials and technology, making us even more skeptical. The Volt is a hugely important car for Chevrolet, and supplementing it with a crossover makes more sense than replacing it with one. Offering one model with a range of powertrain variants like the Hyundai Ioniq and Toyota Prius might be another route GM could take. All six of these vehicles are sedans, Yes, crossover sales are booming, but there's still a huge market for cars. Backing away from these would be essentially giving up sales to competitors from around the globe. The UAW might simply be publicly pushing GM to move crossover production to Hamtramck to avoid closing the plant and laying off workers. Sales of passenger cars are down across both GM and the industry. Consolidating production in other plants and closing Hamtramck rather than having a single facility focus on sedans might make more sense from a business perspective. GM is also trying to reduce its unsold inventory, meaning current production may be slowed or halted while current cars move into customer hands. There's a lot of politics that goes into building a car. GM wants to do what makes the most sense from a business perspective, while the UAW doesn't workers to lose their jobs when a factory closes.

Chevy Volt replacement battery cost varies wildly, up to $34,000

There's a growing hubbub in the plug-in vehicle community over what looks like some ridiculously cheap replacement batteries for the Chevrolet Volt going up for sale. GM Parts Online, for example, is selling a replacement Volt battery with an MSRP of $2,994.64 but, with an online discount, the price comes down to $2,305.88. For the 16-kWh pack in the 2012 Volt, that comes to a very low $144.11 per kilowatt hour (kWH). But is it a real deal? How can it be, when a Chevy dealer may quote you a price of up to $34,000 to replace the pack? For a 16-kWh Volt pack, $2,305.88 comes to a very low $144.11 per kWh. But is it a real deal? Battery packs in alternative propulsion vehicles are usually priced by the kWh and, historically, they've been thought to be in the range of $500-per-kWh for OEM offerings. Since automakers are understandably secretive about their costs, we still don't know what the real number is today, but we do know it varies by automaker. Tesla, for example, has said it pays less than $200-per-kWH at the cell level but, of course, a constructed pack would be more. Whatever is going on, li-ion battery prices are trending downward. So, $144.11 certainly sounds great, but what's the story here? Kevin Kelly, manager of electrification technology communications for General Motors, reminded AutoblogGreen that GM Parts Online is not the official GM parts website and that, "the costs indicated on the site are not what we would charge our dealers or owners for a replacement battery. There would be no cost to the Volt owner if their battery needs replacement or repair while the battery is under the eight year/100,000 mile limited warranty coverage provided by Chevrolet." A single price tag also can't be accurate for everyone, Kelly said. "If the customer needs to have their battery repaired beyond the warranty, the cost to them would vary depending on what needs to be replaced or repaired (i.e. number of modules, which specific internal components need replacement, etc.)." he said. "So, it's hard for us to tell you exactly what the cost would be to the customer because it varies depending on what might need to be repaired/replaced. As a result, the core charge would vary." But, is the $2,300 price even accurate for anyone? Thanks to a reader comment, we see that this similar item on New GM Parts makes it look like the lithium-ion modules that Kelly mentioned – where a lot of the expensive bits are – are not included.