battery CHEVROLET VOLT 2015 2.G Repair Manual

Black plate (1,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-1
Vehicle Care
General Information
General Information . . . . . . . . . . 10-2
California Proposition65 Warning . . . . . . . . . . . . . . . . . 10-2
California Perchlorate Materials Requirements . . . . 10-2
Accessories and Modifications . . . . . . . . . . . . . . . 10-2
Lifting the Vehicle . . . . . . . . . . . . 10-3
Vehicle Checks
Doing Your Own Service Work . . . . . . . . . . . . . . . 10-5
Hood . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Engine Compartment Overview . . . . . . . . . . . . . . . . . . . 10-8
Engine Oil . . . . . . . . . . . . . . . . . . . 10-9
Engine Oil Life System . . . . . 10-12
Engine Air Cleaner/Filter . . . . 10-13
Cooling System (Engine) . . . 10-14
Cooling System (High Voltage Battery) . . . . . . . . . . . 10-15
Cooling System (Power Electronics and Charger
Modules) . . . . . . . . . . . . . . . . . . 10-16
Engine Coolant . . . . . . . . . . . . . 10-17 Engine Overheating . . . . . . . . 10-19
Washer Fluid . . . . . . . . . . . . . . . 10-20
Brakes . . . . . . . . . . . . . . . . . . . . . 10-20
Brake Fluid . . . . . . . . . . . . . . . . . 10-21
Battery . . . . . . . . . . . . . . . . . . . . . 10-23
Electric Drive Unit Shift Lock
Control Function Check . . . 10-25
Park Brake and P (Park) Mechanism Check . . . . . . . . 10-25
Wiper Blade Replacement . . . . . . . . . . . . . . 10-26
Headlamp Aiming
Headlamp Aiming . . . . . . . . . . 10-27
Bulb Replacement
Bulb Replacement . . . . . . . . . . 10-27
Halogen Bulbs . . . . . . . . . . . . . . 10-27
LED Lighting . . . . . . . . . . . . . . . 10-27
Headlamps . . . . . . . . . . . . . . . . . 10-27
Back-Up Lamps . . . . . . . . . . . . 10-28
License Plate Lamp . . . . . . . . 10-29
Replacement Bulbs . . . . . . . . . 10-30
Electrical System
High Voltage Devices andWiring . . . . . . . . . . . . . . . . . . . . . 10-30
Electrical System Overload . . . . . . . . . . . . . . . . . . 10-30 Engine Compartment Fuse
Block . . . . . . . . . . . . . . . . . . . . . 10-31
Instrument Panel Fuse Block (Left Side) . . . . . . . . . . . . . . . . 10-35
Instrument Panel Fuse Block
(Right Side) . . . . . . . . . . . . . . . 10-36
Rear Compartment Fuse Block . . . . . . . . . . . . . . . . . . . . . 10-38
Wheels and Tires
Tires . . . . . . . . . . . . . . . . . . . . . . . . 10-40
All-Season Tires . . . . . . . . . . . . 10-41
Winter Tires . . . . . . . . . . . . . . . . 10-41
Summer Tires . . . . . . . . . . . . . . 10-41
Tire Sidewall Labeling . . . . . . 10-42
Tire Designations . . . . . . . . . . . 10-43
Tire Terminology andDefinitions . . . . . . . . . . . . . . . . 10-43
Tire Pressure . . . . . . . . . . . . . . . 10-46
Tire Pressure Monitor System . . . . . . . . . . . . . . . . . . . 10-47
Tire Pressure Monitor Operation . . . . . . . . . . . . . . . . . 10-48
Tire Inspection . . . . . . . . . . . . . . 10-52
Tire Rotation . . . . . . . . . . . . . . . 10-52
When It Is Time for New Tires . . . . . . . . . . . . . . . . . . . . . . 10-53
Buying New Tires . . . . . . . . . . . 10-54

Black plate (5,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-5
When lifting the vehicle from the
rear, place the service jack directly
under the spring seat.When lifting the vehicle from the
front, place the service jack directly
under the cradle mount. Ramps may
be needed under the front tires to
provide the necessary clearance for
certain service jacks in this location.
For more information, seeDoing
Your Own Service Work on
page 10-5.
Vehicle Checks
Doing Your Own
Service Work
{Warning
Never try to do your own service
on high voltage battery
components. You can be injured
and the vehicle can be damaged
if you try to do your own service
work. Service and repair of these
high voltage battery components
should only be performed by a
trained dealer technician with the
proper knowledge and tools.
Exposure to high voltage can
cause shock, burns, and even
death. The high voltage
components in the vehicle can
only be serviced by technicians
with special training.
(Continued)

Black plate (9,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-9
1. Engine Coolant Surge Tank andPressure Cap. See Engine
Coolant on page 10-17.
2. Engine Air Cleaner/Filter on
page 10-13.
3. Engine Oil Dipstick. See Engine
Oil on page 10-9.
4. High Voltage Battery Coolant Reservoir and Pressure Cap.
See Cooling System (Engine) on
page 10-14 orCooling System
(High Voltage Battery) on
page 10-15 orCooling System
(Power Electronics and Charger
Modules) on page 10-16.
5. Engine Cover.
6. Engine Oil Fill Cap. See Engine
Oil on page 10-9.
7. Power Electronics Coolant Reservoir and Pressure Cap.
See Cooling System (Engine) on
page 10-14 orCooling System
(High Voltage Battery) on
page 10-15 orCooling System
(Power Electronics and Charger
Modules) on page 10-16. 8. Brake Fluid Reservoir. See
“Brake Fluid” underBrakes on
page 10-20.
9. High Voltage Cables (Orange Color).
10. Remote Positive (+) Terminal. SeeJump Starting on
page 10-69.
11. Power Electronics Module.
12. Windshield Washer Fluid Reservoir. See “Adding Washer
Fluid” under Washer Fluid on
page 10-20.
13. Remote Negative (−) Terminal. SeeJump Starting on
page 10-69.
14. Engine Compartment Fuse
Block on page 10-31.Engine Oil
To ensure proper engine
performance and long life, careful
attention must be paid to engine oil.
Following these simple, but
important steps will help protect
your investment:
.Always use engine oil approved
to the proper specification and of
the proper viscosity grade. See
“Selecting the Right Engine Oil”
in this section.
.Check the engine oil level
regularly and maintain the
proper oil level. See “Checking
Engine Oil” and“When to Add
Engine Oil” in this section.
.Change the engine oil at the
appropriate time. See Engine Oil
Life System on page 10-12.
.Always dispose of engine oil
properly. See “What to Do with
Used Oil” in this section.

Black plate (15,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-15
{Warning
Heater and radiator hoses, and
other engine parts, can be very
hot. Do not touch them. If you do,
you can be burned.
Do not run the vehicle if there is a
leak. If you run the engine, it
could lose all coolant. That could
cause an engine fire, and you
could be burned. Get any leak
fixed before you drive the vehicle.
If there seems to be no leak, with
the engine on, check to see if the
cooling fans are running. If the
engine is overheating, the fans
should be running. If it is not, the
vehicle needs service. Turn off the
vehicle.
Cooling System (High
Voltage Battery)
During vehicle operation and also
during charging, the high voltage
battery cells in the vehicle are kept within a normal operating
temperature range. If the
temperature rises above this
temperature, the battery cooling
system turns on the air conditioning
compressor and cools the coolant
until the correct temperature is
reached. If the temperature falls
below this temperature, a high
voltage heater, located in the
battery, heats the coolant until the
correct temperature is reached.
What to Use
The high voltage battery coolant
reservoir in the vehicle is filled with
a 50/50 mixture of DEX-COOL
®
engine coolant and deionized water.
If using this mixture, nothing else
needs to be added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule on
page 11-2.
Checking Coolant
The vehicle must be on a level
surface when checking the coolant
level.
The high voltage battery coolant
reservoir is located in the engine
compartment. See
Engine
Compartment Overview on
page 10-8.
Check to see if coolant is visible in
the high voltage battery coolant
reservoir. If coolant is visible but the

Black plate (16,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
10-16 Vehicle Care
coolant level is below the cold fill
line, there could be a leak in the
cooling system.
The high voltage battery coolant
should only be serviced by a
qualified technician.
Cooling System (Power
Electronics and Charger
Modules)
The power electronics and charger
modules are cooled using the same
coolant loop.
The power electronics and charger
modules in the vehicle are kept
below a maximum temperature.
If the temperature rises above this
temperature, the electric cooling
fans will turn on and cool the
coolant until the correct temperature
is reached.
What to Use
The power electronics and charger
modules coolant reservoir in the
vehicle is filled with a 50/50 mixtureof DEX-COOL engine coolant and
deionized water. If using this
mixture, nothing else needs to be
added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule on
page 11-2.
Checking Coolant
The vehicle must be on a level
surface when checking the coolant
level.
The power electronics and charger
modules coolant reservoir is located
in the engine compartment. See
Engine Compartment Overview on
page 10-8.
Check to see if coolant is visible in
the power electronics and charger
modules coolant reservoir. If coolant
is visible but the coolant level is
below the cold fill line, there could
be a leak in the cooling system.
The power electronics and charger
modules coolant should only be
serviced by a qualified technician.

Black plate (23,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-23
{Caution
.Using the wrong fluid can
badly damage brake
hydraulic system parts. For
example, just a few drops of
mineral-based oil, such as
engine oil, in the brake
hydraulic system can damage
brake hydraulic system parts
so badly that they will have to
be replaced. Do not let
someone put in the wrong
kind of fluid.
.If brake fluid is spilled on the
vehicle's painted surfaces,
the paint finish can be
damaged. Be careful not to
spill brake fluid on the
vehicle. If you do, wash it off
immediately.
Battery
This vehicle has a high voltage
battery and a standard 12-volt
battery.
If the vehicle is in a crash, the
sensing system may shut down the
high voltage system. When this
occurs, the high voltage battery is
disconnected and the vehicle will
not start. The SERVICE VEHICLE
SOON message in the Driver
Information Center (DIC) will be
displayed. Before the vehicle can be
operated again, it must be serviced
at your dealer.
See“If a Crash Occurs” under
Collision Damage Repair on
page 13-9 andHigh Voltage Safety
Information on page 1-18. If an
airbag has inflated, see What Will
You See after an Airbag Inflates? on
page 3-22.
Only a trained service technician
with the proper knowledge and tools
should inspect, test, or replace the
high voltage battery. See your
dealer if the high voltage battery needs service. The dealer has
information on how to recycle the
high voltage battery. There is also
information available at http://
www.recyclemybattery.com.
Keep the vehicle plugged in, even
when fully charged, to keep the high
voltage battery temperature ready
for the next drive. This is important
when outside temperatures are
extremely hot or cold.
A vehicle cover, which can reduce
sun loading on the vehicle and
improve high voltage battery life, is
available from your dealer.
Refer to the replacement number
shown on the original battery label
when a new 12-volt battery is
needed. The vehicle has an
Absorbed Glass Mat (AGM) 12-volt
battery. Installation of a standard
12-volt battery will result in reduced
12-volt battery life.
When using a 12-volt battery
charger on the 12-volt AGM battery,
some chargers have an AGM
battery setting on the charger.

Black plate (24,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
10-24 Vehicle Care
If available, use the AGM setting on
the charger, to limit charge voltage
to 14.8 volts. Follow the charger
manufacturer's instructions.
{Warning
Battery posts, terminals, and
related accessories contain lead
and lead compounds, chemicals
known to the State of California to
cause cancer and reproductive
harm. Wash hands after handling.
Vehicle Storage
{Warning
12‐volt batteries have acid that
can burn you and gas that can
explode. You can be badly hurt if
you are not careful. SeeJump
Starting on page 10-69 for tips on
working around a battery without
getting hurt. Up to four weeks
.Plug in the high voltage battery
charge cord if temperatures will
exceed 35°C (95°F) and keep
the 12-volt battery cables
connected.
Four weeks to 12 months
.Discharge the high voltage
battery until two or three bars
remain on the battery range
indicator (Battery symbol) on the
instrument cluster.
.Do not plug in the high voltage
battery charge cord.
.Remove the black negative (−)
cable from the 12-volt battery
and attach a trickle charger to
the battery terminals or keep the
12-volt battery cables connected
and trickle charge from the
underhood remote positive (+)
and negative (−) terminals. See
Jump Starting on page 10-69 for
the location of these terminals.
{Caution
The vehicle is equipped with an
AGM/VRLA 12-volt battery, which
can be damaged by using the
incorrect type of trickle charger.
An AGM/VRLA-compatible
charger must be used, with the
appropriate setting selected.
Follow the trickle charger
manufacturer instructions.
Reconnecting the 12-Volt Black
Negative Cable
With the 12-volt black negative (−)
cable disconnected, the hatch
cannot be opened by pressing the
hatch release button. If the hatch is
closed and latched, reopen it:
1. Use the door key to open the driver door.
2. Manually unlock and open one of the rear doors.
3. Lower one of the rear seatbacks.

Black plate (25,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-25
4. Pull the load floor cover forwardto access and reconnect the
12-volt battery black negative (−)
cable.
5. After the cable has been connected, open the trunk and
then tighten the cable.
After the battery cable is
reconnected, it is possible that the
vehicle may not operate in Electric
Mode. If this happens, the high
voltage battery may need to be
charged.
Electric Drive Unit Shift
Lock Control Function
Check
{Warning
When you are doing this
inspection, the vehicle could
move suddenly. If the vehicle
moves, you or others could be
injured. 1. Before starting this check, be
sure there is enough room
around the vehicle. It should be
parked on a level surface.
2. Firmly apply the parking brake. See Electric Parking Brake on
page 9-31.
Be ready to apply the regular
brake immediately if the vehicle
begins to move.
3. With the vehicle off and the brake not applied, press and
hold the POWER
Obutton for
more than five seconds to place
the vehicle in Service Only
Mode. See Power Button on
page 9-16. Without applying the
regular brake, try to move the
shift lever out of P (Park) with
normal effort. If the shift lever
moves out of P (Park), contact
your dealer for service.
Park Brake and P (Park)
Mechanism Check
{Warning
When you are doing this check,
the vehicle could begin to move.
You or others could be injured
and property could be damaged.
Make sure there is room in front
of the vehicle in case it begins to
roll. Be ready to apply the regular
brake at once should the vehicle
begin to move.
Park on a fairly steep hill, with the
vehicle facing downhill. Keeping
your foot on the regular brake, set
the electric parking brake.
.To check the electric parking
brake's holding ability: With the
propulsion system active and the
electric drive unit in N (Neutral),
slowly remove foot pressure
from the regular brake pedal. Do
this until the vehicle is held by
the electric parking brake only.

Black plate (32,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
10-32 Vehicle Care
Engine Compartment Fuse Block
A fuse puller is in the engine
compartment fuse block.
The vehicle may not be equipped
with all of the fuses, relays, and
features shown. Mini Fuses Usage
1 Engine Control Module–Switched
Power
2 Emissions
3 Not Used Mini Fuses Usage
4 Ignition Coils/ Injectors
5 Not Used
6a Empty
6b Empty 7 Empty
8 Empty
9 Heated Mirrors
10 Air Conditioning Control Module
11 Traction Power Inverter Module –
Battery
12 Not Used
13 Cabin Heater Pump and Valve
14 Not Used

Black plate (33,1)Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada-7695131) -
2015 - crc - 4/25/14
Vehicle Care 10-33
Mini Fuses Usage15 Traction Power Inverter Module and
Transmission
Control Module –
Battery
17 Engine Control Module–Battery
22 Left High -Beam Headlamp
24 Empty
25 Empty
26 Not Used
31 Not Used
32 Run/Crank –
Sensing Diagnostic
Module (SDM),
Instrument Cluster,
Passenger Airbag
Display, Automatic
Dimming Inside
Rearview Mirror (If
Equipped) Mini Fuses Usage
33 Run/Crank for Vehicle Integration
Control Module
34 Vehicle Integration Control Module –
Battery
35 Not Used
36 Power Electronics Coolant Pump
37 Cabin Heater Control Module
38 Rechargeable Energy Storage
System (High
Voltage Battery)
Coolant Pump
39 Rechargeable Energy Storage
System (High
Voltage Battery)
Control Module
40 Front Windshield Washer Mini Fuses Usage
41 Right High-Beam Headlamp
46 Empty
47 Empty
49 Empty
50 Run/Crank –Rear
Vision Camera,
Accessory Power
Module
51 Run/Crank for ABS/ Rechargeable
Energy Storage
System (High
Voltage Battery)
52 Engine Control Module/
Transmission
Control Module –
Run/Crank
53 Traction Power Inverter Module –
Run/Crank