2016 CHEVROLET VOLT service

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
Vehicle Care 237
{Warning
The electric fans under the hood
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
Heater and radiator hoses, and
other engine parts, can be very
hot. Do not touch them. If you do,
you can be burned. (Continued)
Warning (Continued)
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 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 0324. If using this
mixture, nothing else needs to be
added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule 0315.
Checking Coolant
The vehicle must be on a level
surface when checking the coolant
level.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
238 Vehicle Care
The high voltage battery coolant
reservoir is located in the engine
compartment. SeeEngine
Compartment Overview 0231.
1. High Voltage Battery
Coolant Reservoir Cold
Fill Line
2. Power Electronics Coolant Reservoir Cold Fill Line
Check to see if coolant is visible in
the high voltage battery coolant
reservoir. If coolant is visible but the
coolant level is below the cold fill
line (1), 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
0324. If using this
mixture, nothing else needs to be
added.
The coolant needs to be replaced at
the appropriate interval. See
Maintenance Schedule 0315.
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
0231.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
Vehicle Care 239
1. High Voltage BatteryCoolant Reservoir Cold
Fill Line
2. Power Electronics Coolant Reservoir Cold Fill Line
Check to see if coolant is visible in
the power electronics coolant
reservoir. If coolant is visible but the
coolant level is below the cold fill
line (2), 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 Coolant
The engine cooling system in the
vehicle is filled with GM Premix
DEX-COOL engine coolant. See
Recommended Fluids and
Lubricants
0324. The coolant
requires changing at certain
intervals. See Maintenance
Schedule 0315.
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 0242.
What to Use
{Warning
Adding only plain water or some
other liquid to the cooling system
can be dangerous. Plain water
and other liquids, can boil before
the proper coolant mixture will.
(Continued)
Warning (Continued)
The coolant warning system is set
for the proper coolant mixture.
With plain water or the wrong
mixture, the engine could get too
hot but you would not get the
overheat warning. The engine
could catch fire and you or others
could be burned. Use GM
Premixed DEX-COOL coolant.
Use GM Premix DEX-COOL engine
coolant. If using this mixture,
nothing else needs to be added.
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.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
240 Vehicle Care
Caution
If improper coolant mixture,
inhibitors, or additives are used in
the vehicle cooling system, the
engine could overheat and be
damaged. Too much deionized
water or clean drinkable water
can freeze and crack engine
cooling parts. The repairs would
not be covered by the vehicle
warranty. Use only the proper
mixture of engine coolant for the
cooling system. See
Recommended Fluids and
Lubricants0324.
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 mark, add GM
Premix DEX-COOL engine coolant
at the coolant surge tank, but be
sure the cooling system is cool
before this is done. See Engine
Overheating 0242.
The coolant reservoir is on the
passenger side of the engine
compartment. See Engine
Compartment Overview 0231.
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
You can be burned if you spill
coolant on hot engine parts.
Coolant contains ethylene glycol
and it will burn if the engine parts
are hot enough. Do not spill
coolant on a hot engine.
Caution
This vehicle has a specific
coolant fill procedure. Failure to
follow this procedure could cause
the engine to overheat and be
severely damaged.
{Warning
The electric fans under the hood
can start up even when the
engine is not running and can (Continued)

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
242 Vehicle Care
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
0335.
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 fan is running. If the engine
is overheating, the fan should be
running. If it is not, do not continue
to run the vehicle, and have the
vehicle serviced.
Caution
Running the engine without
coolant may cause damage or a
fire. Vehicle damage would not be
covered by the vehicle warranty.
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.
Adding Washer Fluid
Open the cap with the washer
symbol on it. Add washer fluid until
the tank is full. See Engine
Compartment Overview 0231 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.
. 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
(Continued)

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
Vehicle Care 243
Caution (Continued)
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 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,
inspect brake pads for wear and
evenly tighten wheel nuts in the
proper sequence to torque
specifications. See Capacities and
Specifications 0328.
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 parts are improperly
installed.
Brake Fluid
The brake master cylinder reservoir
is filled with DOT 3 brake fluid as
indicated on the reservoir cap. See
Engine Compartment Overview
0 231 for the location of the
reservoir.
There are only two reasons why the
brake fluid level in the reservoir may
go down:

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
Vehicle Care 245
{Warning
The wrong or contaminated brake
fluid could result in damage to the
brake system. This could result in
the loss of braking leading to a
possible injury. Always use the
proper brake fluid.
Caution
If brake fluid is spilled on the
vehicle's painted surfaces, the
paint finish can be damaged.
Immediately wash off any painted
surface.
Battery - North America
The original equipment battery is
maintenance free. Do not remove
the cap and do not add fluid.
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 0338 and
High Voltage Safety Information
0 19. If an airbag has inflated, see
What Will You See after an Airbag
Inflates? 067.
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.
If available, use the AGM setting on
the charger, to limit charge voltage
to 14.8 volts. Follow the charger
manufacturer's instructions.

Chevrolet VOLT Owner Manual (GMNA-Localizing-U.S/Canada/Mexico-
9159388) - 2016 - crc - 5/20/15
Vehicle Care 247
4. Pull the load floor coverforward to access and
reconnect the 12-volt battery
black negative (−) cable.
5. After the cable has been connected, open the rear hatch
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
0 185.
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 POWER
Ofor more than
five seconds to place the
vehicle in Service Only Mode.
See Power Button 0171.
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 (EPB).
. To check the EPB'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
EPB only.