2016-2018 Chevrolet Volt Service and Repair Manual
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🏷️ Basic Information Identification Make: Chevrolet Model: Volt Generation: Second Generation Model Years Covered: 2016, 2017, 2018 Codes Platform Code: GEM 👋 Introduction Market Position Segment: Plug-in Hybrid Electric Vehicle (PHEV) Target Audience: Environmentally conscious consumers, early adopters of EV technology, tech-savvy drivers Competitive Analysis Key Competitors: Toyota Prius Plug-in Hybrid, Ford C-Max Energi, Hyundai Ioniq Plug-in Hybrid Key Features Unique Selling Proposition: Extended electric-only range compared to many competitors, combination of electric and gasoline power for flexibility Technological Focus: Advanced battery management, efficient electric drive system, sophisticated energy management software 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: Digital (likely PDF, often distributed as such by dealerships) Scope: All models and trims within the specified years Comprehensiveness: A-Z Repairs 📖 Manual Coverage Systems Covered Powertrain: Electric Drive Unit (EDU), Battery Pack, On-Board Charger, Generator/Range Extender Engine, Cooling Systems (Battery, Powertrain), Exhaust System (Range Extender) Chassis: Suspension (Front/Rear), Steering System (Electric Power Steering), Brakes (ABS, Regenerative Braking, Hydraulic Brakes), Wheels, Tires Electrical: 12V Battery System, High Voltage Battery System, Charging System, Body Control Module (BCM), Powertrain Control Module (PCM), Infotainment System, Lighting (Interior/Exterior), HVAC System Controls, Driver Assistance Systems Electronics Body: Exterior Body Panels, Doors, Hood, Trunk Lid, Bumpers, Glass, Interior Trim, Seats, Safety Restraints (Airbags, Seatbelts) Diagnostics: Diagnostic Trouble Codes (DTCs), On-Board Diagnostics (OBD-II), Troubleshooting Flowcharts, Wiring Diagrams, Component Testing Procedures Procedures Included Maintenance: Scheduled Maintenance, Fluid Checks and Replacements, Filter Replacements, Battery Health Checks, Tire Rotation Repair: Component Replacement (e.g., EDU, Battery Modules, Motors, Sensors), System Overhauls, Wiring Harness Repair, Cooling System Servicing, Brake System Bleeding and Pad Replacement Troubleshooting: Diagnosis of common and uncommon faults, symptom-based troubleshooting guides, electrical system fault finding Installation: Installation and removal of major components, accessory installations Technical Depth Depth: Factory-level, comprehensive, from basic diagnostics to complete component overhauls and system recalibrations 📊 Manual Specifications File Format File Type: Likely PDF (searchable text, bookmarked chapters) Print Quality: High-resolution diagrams, schematics, and photographic examples Searchability: Full text search capability for efficient information retrieval Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 1.5L Atkinson-cycle DOHC 4-cylinder (Range Extender Generator) Engine Code: LF4 (specific internal code for the 1.5L Ecotec) Performance Generator Output: Approximately 83 hp (62 kW) Electric Drive Motor Type: Dual Electric Motors (Motor 1: Drive Motor, Motor 2: Generator/Propulsion Assist) Total System Horsepower: 149 hp (111 kW) Total System Torque: 294 lb-ft (400 Nm) Fuel System Fuel Type: Unleaded Gasoline (for range extender) Emission Control System: Catalytic Converter, On-Board Diagnostic (OBD-II) system Cooling System Coolant Type: Dex-Cool (Orange) Extended Life Antifreeze/Coolant Coolant Capacity: Refer to manual for specific engine and battery pack cooling system capacities 🔧 Transmission Standard Transmission Type: Electric Variable Transmission (EVT) with dual motor setup Optional Optional Transmission: N/A (EVT is standard) Features Drive Modes: EV Mode, Sport Mode, Hold Mode, Charge Mode Regenerative Braking: Integrated and adjustable regenerative braking system 📐 Dimensions Exterior Length: 179.1 inches (4549 mm) Width: 70.8 inches (1798 mm) Height: 57.7 inches (1466 mm) Wheelbase: 106.1 inches (2695 mm) Interior Passenger Volume: Approximately 85.1 cubic feet (2409 L) Seating Capacity: 5 passengers Cargo Cargo Volume Rear Seats Up: 19.4 cubic feet (550 L) (with battery pack intrusion) Cargo Volume Rear Seats Down: 33.4 cubic feet (945 L) Weights Curb Weight: Approximately 3,550 lbs (1610 kg) Gross Vehicle Weight Rating: Approximately 4,600 lbs (2087 kg) 🛡️ Safety Features Ratings NHTSA Overall Rating: 5-Star Overall Safety Rating (for 2017 model, generally consistent for period) IIHS Top Safety Pick: Often awarded Top Safety Pick or Top Safety Pick+ for these model years Active Features ABS: Standard Anti-lock Braking System Esc: Standard Electronic Stability Control (StabiliTrak) Traction Control: Standard Traction Control Driver Assistance: Available Forward Collision Alert, Lane Departure Warning, Lane Keep Assist, Rear Cross-Traffic Alert, Side Blind Zone Alert Passive Features Airbags: Driver and front passenger airbags, front side-impact airbags, front and rear head curtain airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters, LATCH system for child seats 💡 Technology Features Infotainment Infotainment System: Chevrolet MyLink infotainment system with 8-inch color touchscreen Smartphone Integration: Apple CarPlay and Android Auto compatibility Navigation: Optional factory navigation system Driver Assistance Adas Suite: Optional advanced driver-assistance systems including Forward Collision Alert, Lane Departure Warning, and Lane Keep Assist. Connectivity Wi Fi Hotspot: Available 4G LTE Wi-Fi hotspot Charging Technology Charging Connector Type: SAE J1772 (Level 1 & Level 2 charging) Charging Times: Level 2 charging (240V) typically takes around 2.5-3 hours for a full charge. 🔧 Maintenance Service Intervals Oil Change Interval Range Extender: Typically every 7,500 miles or 12 months, whichever comes first (refer to manual for exact specification based on driving conditions). Tire Rotation Interval: Every 7,500 miles Cabin Air Filter Replacement: Every 24,000 miles or 24 months Engine Air...
Environmentally conscious consumers, early adopters of EV technology, tech-savvy drivers
Competitive Analysis
Key Competitors:
Toyota Prius Plug-in Hybrid, Ford C-Max Energi, Hyundai Ioniq Plug-in Hybrid
Key Features
Unique Selling Proposition:
Extended electric-only range compared to many competitors, combination of electric and gasoline power for flexibility
Technological Focus:
Advanced battery management, efficient electric drive system, sophisticated energy management software
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Digital (likely PDF, often distributed as such by dealerships)
Scope:
All models and trims within the specified years
Comprehensiveness:
A-Z Repairs
📖 Manual Coverage
Systems Covered
Powertrain:
Electric Drive Unit (EDU), Battery Pack, On-Board Charger, Generator/Range Extender Engine, Cooling Systems (Battery, Powertrain), Exhaust System (Range Extender)
Chassis:
Suspension (Front/Rear), Steering System (Electric Power Steering), Brakes (ABS, Regenerative Braking, Hydraulic Brakes), Wheels, Tires
Electrical:
12V Battery System, High Voltage Battery System, Charging System, Body Control Module (BCM), Powertrain Control Module (PCM), Infotainment System, Lighting (Interior/Exterior), HVAC System Controls, Driver Assistance Systems Electronics
Scheduled Maintenance, Fluid Checks and Replacements, Filter Replacements, Battery Health Checks, Tire Rotation
Repair:
Component Replacement (e.g., EDU, Battery Modules, Motors, Sensors), System Overhauls, Wiring Harness Repair, Cooling System Servicing, Brake System Bleeding and Pad Replacement
Troubleshooting:
Diagnosis of common and uncommon faults, symptom-based troubleshooting guides, electrical system fault finding
Installation:
Installation and removal of major components, accessory installations
Technical Depth
Depth:
Factory-level, comprehensive, from basic diagnostics to complete component overhauls and system recalibrations
📊 Manual Specifications
File Format
File Type:
Likely PDF (searchable text, bookmarked chapters)
Print Quality:
High-resolution diagrams, schematics, and photographic examples
Searchability:
Full text search capability for efficient information retrieval
5-Star Overall Safety Rating (for 2017 model, generally consistent for period)
IIHS Top Safety Pick:
Often awarded Top Safety Pick or Top Safety Pick+ for these model years
Active Features
ABS:
Standard Anti-lock Braking System
Esc:
Standard Electronic Stability Control (StabiliTrak)
Traction Control:
Standard Traction Control
Driver Assistance:
Available Forward Collision Alert, Lane Departure Warning, Lane Keep Assist, Rear Cross-Traffic Alert, Side Blind Zone Alert
Passive Features
Airbags:
Driver and front passenger airbags, front side-impact airbags, front and rear head curtain airbags
Seatbelts:
3-point seatbelts with pretensioners and load limiters, LATCH system for child seats
💡 Technology Features
Infotainment
Infotainment System:
Chevrolet MyLink infotainment system with 8-inch color touchscreen
Smartphone Integration:
Apple CarPlay and Android Auto compatibility
Navigation:
Optional factory navigation system
Driver Assistance
Adas Suite:
Optional advanced driver-assistance systems including Forward Collision Alert, Lane Departure Warning, and Lane Keep Assist.
Connectivity
Wi Fi Hotspot:
Available 4G LTE Wi-Fi hotspot
Charging Technology
Charging Connector Type:
SAE J1772 (Level 1 & Level 2 charging)
Charging Times:
Level 2 charging (240V) typically takes around 2.5-3 hours for a full charge.
🔧 Maintenance
Service Intervals
Oil Change Interval Range Extender:
Typically every 7,500 miles or 12 months, whichever comes first (refer to manual for exact specification based on driving conditions).
Tire Rotation Interval:
Every 7,500 miles
Cabin Air Filter Replacement:
Every 24,000 miles or 24 months
Engine Air Filter Replacement:
Every 30,000 miles (for range extender)
Fluid Specifications
Engine Oil Type:
SAE 0W-16 (GM P/N 19373392 or equivalent)
Engine Oil Capacity:
4.2 US quarts (4.0 L) with filter change (for 1.5L range extender)
Transmission Fluid Type:
GM DEXRON-VI Automatic Transmission Fluid (ATF) (for electric drive unit cooling and lubrication)
Brake Fluid Type:
DOT 3 or DOT 4 Heavy Duty Brake Fluid
Known Issues
Battery Health Monitoring:
While generally robust, the manual will detail procedures for monitoring battery health and addressing any degradation issues.
Software Updates:
Regular software updates from GM address system performance, battery management, and occasional drivability concerns.
Range Extender Engine Maintenance:
Proper maintenance of the 1.5L engine is crucial for its longevity, including oil changes and filter replacements as per schedule.
📚 Vehicle History
Brand Heritage
Chevrolet Ev History:
Chevrolet has a long history in automotive innovation, with the Volt representing a significant step into the modern electrified vehicle era.
Model Evolution
Volt Generation 1 To 2:
The 2016-2018 models represent the second generation, featuring a significantly redesigned powertrain for increased electric range, improved efficiency, and a more conventional compact car design.
Battery Technology Advancement:
Second-gen Volt featured a larger battery pack (18.4 kWh) compared to the first generation (16.5 kWh), enabling up to 53 miles of electric-only range.
Production
Manufacturing Location:
Detroit-Hamtramck Assembly Plant, Michigan, USA
Production Start Year:
2010 (First Generation), 2015 (Second Generation for 2016 model year)
🏆 Awards & Recognition
Recognitions
Green Car Of The Year:
While not always winning the top prize, the Volt has been a consistent contender and recognized for its environmental credentials.
Ratings
Epa Fuel Economy Electric:
106 MPGe combined (electric)
Epa Fuel Economy Hybrid:
42 MPG combined (gasoline)
Certifications
California Pzev:
Eligible for certain PZEV (Partial Zero Emission Vehicle) or SULEV (Super Ultra Low Emission Vehicle) classifications in specific states.
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