engine CHEVROLET VOLT 2018 Repair Manual

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
244 Vehicle Care
filter, make sure that the engine air
cleaner/filter housing and nearby
components are free of dirt and
debris. Remove the engine air
cleaner/filter. Lightly tap and shake
the engine air cleaner/filter (away
from the vehicle), to release loose
dust and dirt. Inspect the engine air
cleaner/filter for damage, and
replace if damaged. Do not clean
the engine air cleaner/filter or
components with water or
compressed air.
To inspect or replace the air filter:1. Open the hood. See Hood
0 237.
2. Locate the engine air cleaner/ filter assembly on the
passenger side of the engine
compartment. See Engine
Compartment Overview 0239.
3. Remove the five screws and lift
the air cleaner/filter cover from
the air cleaner/filter housing
assembly.
How to Reinstall the Engine
Air Filter
1. Install the air filter into theengine air cleaner/filter
assembly. The outer air filter
seal must be fitted properly in
the engine air cleaner/filter
assembly.
2. Replace the air cleaner/filter cover by lowering it to meet the
bottom of the engine air
cleaner/filter housing assembly. 3. Install the five screws to secure
the air cleaner/filter cover to
the air cleaner/filter housing
assembly.
{Warning
Operating the engine with the air
cleaner/filter off can cause you or
others to be burned. The air
cleaner not only cleans the air; it
helps to stop flames if the engine
backfires. Use caution when
working on the engine and do not
drive with the air cleaner/filter off.
Caution
If the air cleaner/filter is off, dirt
can easily get into the engine,
which could damage it. Always
have the air cleaner/filter in place
when driving.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
Vehicle Care 245
Cooling System (Engine)
1. Engine Cooling Fans (Outof View)
2. Engine Coolant Surge Tank and Pressure Cap
{Warning
An underhood electric fan can
start up even when the engine is
not running and can cause injury.
Keep hands, clothing, and tools
away from any underhood
electric fan. If the coolant inside the coolant
surge tank is boiling, do not do
anything else until it cools down.
The vehicle should be parked on a
level surface.
The coolant level should be up to
the cold fill line. If it is not, there
might be a leak at the radiator
hoses, heater hoses, radiator, water
pump, or somewhere else in the
cooling system.
{Warning
Do not touch heater or radiator
hoses, or other engine parts.
They can be very hot and can
burn you. Do not run the engine if
there is a leak; all coolant could
leak out. That could cause an
engine fire and can burn you. Fix
any leak before driving 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 they are not,
the vehicle needs service. Turn off
the vehicle.
Engine Coolant
The engine cooling system in the
vehicle is filled with GM Premix
DEX-COOL engine coolant. See
Recommended Fluids and
Lubricants
0335. The coolant
requires changing at certain
intervals. See Maintenance
Schedule 0327.
The following explains the cooling
system and how to check and add
coolant when it is low. If there is a
problem with engine overheating,
see Engine Overheating 0250.
What to Use
{Warning
Plain water, or other liquids such
as alcohol, can boil before the
proper coolant mixture will. With
plain water or the wrong mixture,
the engine could get too hot but
(Continued)

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
246 Vehicle Care
Warning (Continued)
there would not be an overheat
warning. The engine could catch
fire and you or others could be
burned.
Use GM Premix DEX-COOL engine
coolant. This mixture:
. Gives freezing protection down
to−37 °C (−34 °F), outside
temperature.
. Gives boiling protection up to
129 °C (265 °F), engine
temperature.
. Protects against rust and
corrosion.
. Will not damage aluminum parts.
. Helps keep the proper engine
temperature.
Caution
Do not use anything other than a
pre-mix of DEX-COOL coolant
that meets GM Standard
GMW3420 and deionized water.
Anything else can cause damage
to the hybrid cooling system
components and the vehicle,
which would not be covered by
the vehicle warranty.
Never dispose of engine coolant by
putting it in the trash, pouring it on
the ground, or into sewers, streams,
or bodies of water. Have the coolant
changed by an authorized service
center, familiar with legal
requirements regarding used
coolant disposal. This will help
protect the environment and your
health.
Checking Coolant
The vehicle must be on a level
surface when checking the coolant
level. Check to see if coolant is visible in
the coolant surge tank. If the coolant
inside the coolant surge tank is
boiling, do not do anything else until
it cools down. If coolant is visible
but the coolant level is not at or
above the cold fill line, add GM
Premix DEX-COOL engine coolant.
Be sure the cooling system is cool
before this is done. See
Engine
Overheating 0250.
The coolant surge tank is on the
driver side of the engine
compartment. See Engine
Compartment Overview 0239.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
Vehicle Care 247
The coolant level should be at or
above the cold fill line on the
coolant surge tank. If it is not, there
could be a leak in the cooling
system.
How to Add Coolant to the
Coolant Surge Tank
{Warning
Spilling coolant on hot engine
parts can burn you. Coolant
contains ethylene glycol and it will
burn if the engine parts are hot
enough.
{Warning
An underhood electric fan can
start up even when the engine is
not running and can cause injury.
Keep hands, clothing, and tools
away from any underhood
electric fan.
{Warning
Steam and scalding liquids from a
hot cooling system are under
pressure. Turning the pressure
cap, even a little, can cause them
to come out at high speed and
you could be burned. Never turn
the cap when the cooling system,
including the pressure cap, is hot.
Wait for the cooling system and
pressure cap to cool.
Caution
Failure to follow the specific
coolant fill procedure could cause
system damage. If coolant is not
visible in the hybrid surge tank(s),
contact your dealer.
If coolant is needed, add the proper
GM Premix DEX-COOL engine
coolant at the coolant surge tank.
The coolant surge tank pressure
cap can be removed when the
cooling system, including the surge
tank pressure cap and upper
radiator hose, is no longer hot. 1. Turn the pressure cap slowly counterclockwise. If a hiss is
heard, wait for that to stop.
A hiss means there is still
some pressure left.
2. Keep turning the cap and remove it.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
248 Vehicle Care
3. Fill the coolant surge tank withthe proper mixture to the cold
fill line.
4. Replace the pressure cap. Be sure the pressure cap is
hand-tight and fully seated.
Caution
If the pressure cap is not tightly
installed, coolant loss and engine
damage may occur. Be sure the
cap is properly and tightly
secured.
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 high
voltage battery cell temperature
rises above the normal operating
temperature range, the battery
cooling system turns on the air
conditioning compressor and cools
the coolant until the correct battery
cell temperature is reached. If the
high voltage battery cell temperature
falls below the normal operating
temperature range, a high voltage
heater, located in the battery, heats
the coolant until the correct battery
cell temperature is reached.
During high voltage battery system
cooling, you may feel temperature
changes at the air vents due to the
extra load on the system.
What to Use
The high voltage battery coolant
reservoir in the vehicle is filled with
GM Premix DEX-COOL engine
coolant. See Recommended Fluids
and Lubricants 0335. If using this
mixture, nothing else needs to be
added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule 0327.
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 0239.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
Vehicle Care 249
1. High Voltage BatteryCoolant Reservoir
2. Power Electronics Coolant Reservoir
Check to see if coolant is visible in
the high voltage battery coolant
reservoir (1). If coolant is visible but
the coolant level is below the cold
fill line on the side of the reservoir,
there could be a leak in the cooling
system.
The high voltage battery cooling
system supports the operation of
sensitive electronics that are critical
to vehicle operation. The high voltage battery cooling
system 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
threshold. If the coolant temperature
rises above this temperature
threshold, 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 GM Premix
DEX-COOL engine coolant. See
Recommended Fluids and
Lubricants
0335. If using this
mixture, nothing else needs to be
added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule 0327.
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
0239.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
250 Vehicle Care
1. High Voltage BatteryCoolant Reservoir
2. Power Electronics Coolant Reservoir
Check to see if coolant is visible in
the power electronics coolant
reservoir (2). If coolant is visible but
the coolant level is below the cold
fill line on the side of the reservoir,
there could be a leak in the cooling
system.
The power electronics cooling
system supports the operation of
sensitive electronics. The power electronics cooling
system should only be serviced by a
qualified technician.
Engine Overheating
The vehicle has an indicator to warn
of engine overheating.
If the decision is made not to lift the
hood when this warning appears,
get service help right away. See
Roadside Assistance Program
0
345.
If the decision is made to lift the
hood, make sure the vehicle is
parked on a level surface.
Then check to see if the engine
cooling fans are running. If the
engine is overheating, the fans
should be running. If they are not,
do not continue to run the vehicle,
and have the vehicle serviced.
Caution
Do not run the engine when there
is a leak in the hybrid cooling
system. This can cause a loss of
all coolant and can damage the
system and the vehicle. Have any
leaks fixed right away.
Washer Fluid
What to Use
When adding windshield washer
fluid to the vehicle, be sure to read
the manufacturer's instructions
before use. If operating the vehicle
in an area where the temperature
may fall below freezing, use a fluid
that has sufficient protection against
freezing.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
Vehicle Care 251
Adding Washer Fluid
Open the cap with the washer
symbol on it. Add washer fluid until
the tank is full. SeeEngine
Compartment Overview 0239 for
reservoir location.
Caution
. Do not use washer fluid that
contains any type of water
repellent coating. This can
cause the wiper blades to
chatter or skip.
. Do not use engine coolant
(antifreeze) in the
windshield washer. It can
damage the windshield
washer system and paint.
(Continued)
Caution (Continued)
.Do not mix water with
ready-to-use washer fluid.
Water can cause the
solution to freeze and
damage the washer fluid
tank and other parts of the
washer system.
. When using concentrated
washer fluid, follow the
manufacturer instructions for
adding water.
. Fill the washer fluid tank
only three-quarters full when
it is very cold. This allows
for fluid expansion if
freezing occurs, which could
damage the tank if it is
completely full.
Brakes
Disc brake pads have built-in wear
indicators that make a high-pitched
warning sound when the brake pads
are worn and new pads are needed.
The sound can come and go or can be heard all the time when the
vehicle is moving, except when
applying the brake pedal firmly.
{Warning
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
a crash. When the brake wear
warning sound is heard, have the
vehicle serviced.
Caution
Continuing to drive with worn-out
brake pads could result in costly
brake repair.
Some driving conditions or climates
can cause a brake squeal when the
brakes are first applied or lightly
applied. This does not mean
something is wrong with the brakes.
Properly torqued wheel nuts are
necessary to help prevent brake
pulsation. When tires are rotated,

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
252 Vehicle Care
inspect brake pads for wear and
evenly tighten wheel nuts in the
proper sequence to torque
specifications. SeeCapacities and
Specifications 0339.
Brake pads should be replaced as
complete sets.
Brake Pedal Travel
See your dealer if the brake pedal
does not return to normal height,
or if there is a rapid increase in
pedal travel. This could be a sign
that brake service may be required.
Replacing Brake System Parts
Always replace brake system parts
with new, approved replacement
parts. If this is not done, the brakes
may not work properly. The braking
performance expected can change
in many other ways if the wrong
replacement brake parts are
installed or if parts are improperly
installed.
Brake Fluid
The brake master cylinder reservoir
is filled with GM approved DOT 3
brake fluid as indicated on the
reservoir cap. See Engine
Compartment Overview 0239 for
the location of the reservoir.
Checking Brake Fluid
With the vehicle in P (Park) on a
level surface, the brake fluid level
should be between the minimum
and maximum marks on the brake
fluid reservoir.
There are only two reasons why the
brake fluid level in the reservoir may
go down:
. Normal brake lining wear. When
new linings are installed, the
fluid level goes back up. .
A fluid leak in the brake
hydraulic system. Have the
brake hydraulic system fixed.
With a leak, the brakes will not
work well.
Always clean the brake fluid
reservoir cap and the area around
the cap before removing it.
Do not top off the brake fluid.
Adding fluid does not correct a leak.
If fluid is added when the linings are
worn, there will be too much fluid
when new brake linings are
installed. Add or remove fluid, as
necessary, only when work is done
on the brake hydraulic system.
{Warning
If too much brake fluid is added, it
can spill on the engine and burn,
if the engine is hot enough. You
or others could be burned, and
the vehicle could be damaged.
Add brake fluid only when work is
done on the brake hydraulic
system.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S./Canada/Mexico-
11349113) - 2018 - crc - 10/12/17
262 Vehicle Care
If the overload is caused by an
electrical problem and not snow or
ice, be sure to get it fixed.
Fuses and Circuit
Breakers
The wiring circuits in the vehicle are
protected from short circuits by a
combination of fuses and circuit
breakers. This greatly reduces the
chance of damage caused by
electrical problems.
{Danger
Fuses and circuit breakers are
marked with their ampere rating.
Do not exceed the
specified amperage rating when
replacing fuses and circuit
breakers. Use of an oversized
fuse or circuit breaker can result
in a vehicle fire. You and others
could be seriously injured or
killed.To check a fuse, look at the
silver-colored band inside the fuse.
If the band is broken or melted,
replace the fuse. Be sure to replace
a bad fuse with a new one of the
identical size and rating.
Fuses of the same amperage can
be temporarily borrowed from
another fuse location, if a fuse goes
out. Replace the fuse as soon as
possible.
Engine Compartment
Fuse Block
To open the fuse block cover, press
the clips at the side and back and
pull the cover up.
Caution
Spilling liquid on any electrical
component on the vehicle may
damage it. Always keep the
covers on any electrical
component.