2011 Chevrolet Volt Service & Repair Manual

Volt Title Page 2012 Chevrolet Volt / Opel Ampera Service Manual Volume 1 Foreword This manual provides information on the diagnosis, service procedures, adjustments, and specifications for the 2012 Volt / Ampera. The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better serve the vehicle owners. When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes at any time without notice. Published by North American Operations General Motors Corporation Warren, Michigan 48090 ©2010 GENERAL MOTORS ALL RIGHTS RESERVED The information cut-off date is 09/19/08. LITHO IN U.S.A. No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means including, but not limited to, electronic, mechanical, photocopying, and recording without the prior written permission of General Motors. This applies to all text, illustrations, and tables.

Volt Definition of Danger, Warning, Caution, and Note The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers, Warnings, Cautions, Notes or Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Dangers, Warnings, Cautions and Notes or Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring: • Serious bodily injury or death to the technician • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper repair or replacement of vehicle components. • Any warning or caution that appears in this service category is referenced from the individual service categories. DANGER Defined When encountering a DANGER, you will be asked to take a necessary action or not to take a prohibited action. If a DANGER is not heeded, the following consequences may occur: • Serious bodily injury or death to the technician • Serious bodily injury or death to other technicians in the workplace area WARNING Defined When encountering a WARNING, you will be asked to take a necessary action or not to take a prohibited action. If a WARNING is not heeded, the following consequences may occur: • Serious bodily injury to the technician • Serious bodily injury to other technicians in the workplace area • Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired CAUTION Defined

CAUTIONS call special attention to a necessary action or to a prohibited action. If a CAUTION is not heeded, the following consequences may occur: • Damage to the vehicle • Unnecessary vehicle repairs • Unnecessary component replacement • Improper operation or performance of the system or component under repair • Damage to any systems or components which are dependent upon the proper operation of the system or component under repair • Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair • Damage to fasteners, basic tools, or special tools • The leakage of coolant, lubricant, or other vital fluids NOTE or IMPORTANT Defined NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. NOTE or IMPORTANT statements are designed to do the following: • Clarify a procedure • Present additional information for accomplishing a procedure • Give insight into the reason or reasons for performing a procedure in the manner recommended • Present information that will help to accomplish a procedure in a more effective manner • Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease &#169© Copyright Chevrolet. All rights reserved

Volt ABS Component Handling Warning Warning: Certain components in the Antilock Brake System (ABS) are not intended to be serviced individually. Attempting to remove or disconnect certain system components may result in personal injury and/or improper system operation. Only those components with approved removal and installation procedures should be serviced. © Copyright Chevrolet. All rights reserved

Volt Actions to Take When Working with Fuel Warning Warning: Fuel Vapours can collect while servicing fuel system parts in enclosed areas such as a boot. To reduce the risk of fire and increased exposure to vapours: • Use forced air ventilation such as a fan set outside of the boot. • Plug or cap any fuel system openings in order to reduce fuel vapour formation. • Clean up any spilled fuel immediately. • Avoid sparks and any source of ignition. • Use signs to alert others in the work area that fuel system work is in process. &#169© Copyright Chevrolet. All rights reserved

Volt Approved Equipment for Collision Repair Warning Warning: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and protective clothing. © Copyright Chevrolet. All rights reserved

Volt Assistant Driving Warning Warning: An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result. © Copyright Chevrolet. All rights reserved

Volt Battery Disconnect Warning Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. For Vehicles equipped with OnStar® (UE1) with Back Up Battery: The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced. © Copyright Chevrolet. All rights reserved

Volt Brake Dust Warning Warning: Avoid taking the following actions when you service wheel brake parts: • Do not grind brake linings. • Do not sand brake linings. • Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. &#169© Copyright Chevrolet. All rights reserved

2011 Chevrolet Volt Service & Repair Manual

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