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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...
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2016-2018 Chevrolet Volt Service and Repair Manual
🏷️ 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 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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