2011 CHEVROLET VOLT service

Black plate (23,1)Chevrolet Volt Owner Manual - 2011
Vehicle Care 10-23
If coolant is needed, add the proper
DEX-COOL coolant mixture 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 slowlycounterclockwise. 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.
3. Fill the coolant surge tank with
the proper mixture to the cold
fill line.
4. Replace the pressure cap. Be sure the pressure cap is
hand‐tight and fully seated.
Notice: If the pressure cap is
not tightly installed, coolant loss
and possible engine damage may
occur. Be sure the cap is properly
and tightly secured.
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 on page 13‑6.
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.
Notice: Engine damage from
running the engine without
coolant is not covered by the
warranty.

Black plate (25,1)Chevrolet Volt Owner Manual - 2011
Vehicle Care 10-25
Brakes
This vehicle has disc 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 be
heard all the time 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.
Notice: 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,
inspect brake pads for wear and
evenly tighten wheel nuts in
the proper sequence to torque
specifications in
Capacities and
Specifications on page 12‑2.
Brake linings should always be
replaced as complete axle 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 might
be required.
Brake Adjustment
Every time the brakes are applied,
with or without the vehicle moving,
the brakes adjust for wear.
Replacing Brake System Parts
The braking system on a vehicle is
complex. Its many parts have to be
of top quality and work well together
if the vehicle is to have really good
braking. The vehicle was designed
and tested with top-quality brake
parts. When parts of the braking
system are replaced, be sure to get
new, approved replacement parts.
If this is not done, the brakes might
not work properly. For example,
installing disc brake pads that are
wrong for the vehicle, can change
the balance between the front
and rear brakes —for the worse.
The braking performance expected
can change in many other ways if
the wrong replacement brake parts
are installed.

Black plate (28,1)Chevrolet Volt Owner Manual - 2011
10-28 Vehicle Care
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 13‑10 for additional
information. If an airbag has
inflated, see What Will You See
after an Airbag Inflates? on
page 3‑31. 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.{DANGER
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. See
Jump
Starting on page 10‑79 for tips on
working around a battery without
getting hurt.

Black plate (29,1)Chevrolet Volt Owner Manual - 2011
Vehicle Care 10-29
Extended Storage
Remove the 12‐volt battery black,
negative (−) cable from the battery
to keep the 12‐volt battery from
running down or use a battery
trickle charger.
In addition, to avoid potential
damage to the high voltage battery,
perform the following recommended
steps:
.Store the high voltage battery
with 1/2 charge or less.
.Always store the vehicle in an
environment between−10°C
(14°F) and 30°C (86°F).
.Vehicle storage at extreme
temperatures can cause damage
to the high voltage battery.
Remember to reconnect the 12‐volt
battery when ready to drive the
vehicle.
Propulsion System Start
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. 2. Firmly apply both the electric
parking brake and the regular
brake. See Electric Parking
Brake on page 9‑35.
Do not use the accelerator
pedal, and be ready to turn
off the propulsion system
immediately if it starts.
3. Try to start the propulsion system in each gear. The vehicle
should start only in P (Park) or
N (Neutral). If the vehicle starts
in any other position, contact
your dealer for service.

Black plate (30,1)Chevrolet Volt Owner Manual - 2011
10-30 Vehicle Care
Electrical 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 9‑35.
Be ready to apply the regular
brake immediately if the vehicle
begins to move.
3. With the vehicle off and the brake not applied, push the
power button to ON/RUN without
starting the vehicle. See Power
Button on page 9‑18. 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.

Black plate (31,1)Chevrolet Volt Owner Manual - 2011
Vehicle Care 10-31
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.
.To check the P (Park)
mechanism's holding ability:
With the propulsion system
active, shift to P (Park).
Then release the electric
parking brake followed by
the regular brake.
Contact your dealer if service is
required.
Wiper Blade Replacement
Windshield wiper blades should be
inspected for wear and cracking.
See Scheduled Maintenance on
page 11‑2 for more information.
Replacement blades come in
different types and are removed
in different ways. For proper type
and length, see Maintenance
Replacement Parts on page 11‑7.
Notice: Allowing the wiper blade
arm to touch the windshield
when no wiper blade is installed
could damage the windshield.
Any damage that occurs would
not be covered by your warranty.
Do not allow the wiper blade arm
to touch the windshield.
To replace the windshield wiper
blade:
1. Pull the windshield wiper
assembly away from the
windshield.
2. Press the button in the middle ofthe wiper arm connector, and
pull the wiper blade away from
the arm connector.
3. Remove the wiper blade.
4. Reverse Steps 1 through 3 for wiper blade replacement.

Black plate (37,1)Chevrolet Volt Owner Manual - 2011
Vehicle Care 10-37
6. Reinstall the lamp assembly (C)into the fascia by inserting the
left side first.
7. Push the spring clip side into place.
Replacement Bulbs
Exterior Lamp Bulb
Number
Back-Up Lamps 3157K
High/Low‐Beam
Headlamps HIR2 (9012)
License Plate
Lamps 168LL
(W5W)
For replacement bulbs not listed
here, contact your dealer.
Electrical System
High Voltage Devices and
Wiring
{WARNING
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.
High voltage components are
identified by labels. Do not
remove, open, take apart,
or modify these components.
High voltage cable or wiring has
orange covering. Do not probe,
tamper with, cut, or modify high
voltage cable or wiring.
Electrical System
Overload
The vehicle has fuses and circuit
breakers to protect against an
electrical system overload.
When the current electrical load is
too heavy, the circuit breaker opens
and closes, protecting the circuit
until the current load returns to
normal or the problem is fixed.
This greatly reduces the chance
of circuit overload and fire caused
by electrical problems.
Fuses and circuit breakers protect
the following in the vehicle:
.Headlamp Wiring
.Windshield Wiper Motor
.Power Windows and other
Power Accessories
Replace a bad fuse with a new one
of the identical size and rating.

Black plate (48,1)Chevrolet Volt Owner Manual - 2011
10-48 Vehicle Care
Wheels and Tires
Tires
Every new GM vehicle has
high-quality tires made by
a leading tire manufacturer.
See the warranty manual
for information regarding
the tire warranty and where
to get service. For additional
information refer to the tire
manufacturer.
{WARNING
.Poorly maintained and
improperly used tires are
dangerous.(Continued)
WARNING (Continued)
.Overloading the tires can
cause overheating as a
result of too much flexing.
There could be a blowout and
a serious crash. See Vehicle
Load Limits on page 9‑14.
.Underinflated tires pose the
same danger as overloaded
tires. The resulting crash
could cause serious injury.
Check all tires frequently to
maintain the recommended
pressure. Tire pressure
should be checked when
the tires are cold.
.Overinflated tires are more
likely to be cut, punctured,
or broken by a sudden
impact —such as when
hitting a pothole. Keep
tires at the recommended
pressure.
(Continued)
WARNING (Continued)
.Worn or old tires can cause
a crash. If the tread is badly
worn, replace them.
.Replace any tires that have
been damaged by impacts
with potholes, curbs, etc.
.Improperly repaired tires
can cause a crash. Only the
dealer or an authorized tire
service center should repair,
replace, dismount, and mount
the tires.
.Do not spin the tires in
excess of 55 km/h (35 mph)
on slippery surfaces such
as snow, mud, ice, etc.
Excessive spinning may
cause the tires to explode.