General Information: Other Chevrolet Volt I

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

Scheme 2

Customer Concern Verification Sheets

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

The GM-wide Customer Concern Verification Sheets are available in GM GlobalConnect. The Customer Concern Verification Sheets may be printed and reproduced locally.

Dealers

All U.S. Dealers participating in the Common Training Program can enroll through the Common Training System Website at https://www.gmtraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about Common Training should contact the Common Training help desk at 1-888-748-2687. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010.

Fleets

GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through Common Training/GM Service Technical College (STC).

Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmtraining.com using the "Contact Us" button on the site and/or the Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831.

Most GM STC course materials have associated charges.

To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831.

Non-GM Dealer Technicians

Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry.

ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information.

Scheme 3

The vehicle identification number (VIN) plate (1) is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle.

Scheme 4

The stamping is located on the front floor panel under the front right-hand floor mat. It can be seen under the VIN Plate Opening Access Cover (1).

1.4L (LUU) Engine ID and VIN Derivative Location

Refer to Engine Identification .

Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

Scheme 5

Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label

RPO Code List

RPO Code List

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Scheme 6

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Thread Inserts

General Purpose Thread Repair Kits.

These kits are available commercially.

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Registered and Non-Registered Trademarks

Door Lock and Ignition Lock Folding and Non-Folding Key Cutting

High Security keys are available from the service parts system.

Obtain the key code from the security card or from the GM Dealer World, Parts, Key Code Look Up system.

If you have the key code and access to a Triax-E., BD Laser or other code key cutting machine from the GM Dealer Equipment Catalog, you may cut a new key.

If you have the original key and access to a Matrix S, BD Laser or other key duplicating machine, you may duplicate the key.

If you do not have a high security key cutting machine, order the side cut key from the service parts system. Include the key code in the NOTE field. Indicate the timing and the method of the shipment.

Inspect the new key operation in the lock cylinder. Ensure the new key operates effectively.

Front Side Door Lock Cylinder Coding (Free Wheeling)

Special Tools

BO-49753 Assembly Tool

Scheme 7

The door lock cylinder uses 8 of the 8 cut positions. The tumbler positions are staggered from side to side, 4 on one side and 4 on the other, are not self-retaining, and are not snap in.

1. Hold the door lock cylinder (1) so the side with the 4 tumbler spring pockets faces up, pocket nearest to the cylinder head.
2. Insert the tumbler springs (2) into the 4 spring pockets. This side uses left tumblers.
3. Install the tumbler (3) for key cut position one in the slot nearest to the front of the lock cylinder. Install the remaining tumblers, key cut positions 3, 5, and 7, following the key code and same process. Press the tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 4 tumbler spring wells faces up. This side uses right tumblers.
6. Insert the tumbler springs into the 4 spring pockets.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the second key cut position, the second number in the key code. Install the remaining tumblers for the key cut positions 4, 6, and 8. Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
9. Insert the key and lightly lubricate the cylinder body diameter and tumbler surfaces and a small amount in the head of the cylinder using the supplied grease.
10. Insert the sleeve (4) onto the cylinder assembly.
11. Insert the clutch (5) and driver (6) onto the cylinder (1).
12. Load the cylinder into the BO-49753 assembly tool so that the clutch (1) indexes with the notch in the opening of the tool (2).
13. Load the assembly tool with the lock cylinder into a vice and tighten the vice ONLY enough to hold the tool and lock the cylinder in place.
14. Insert the roll pin (7) into the driver (6) and install it using a 1/16 inch pin punch.
15. Insert the buffer (8) in the case (9), verify the buffer is properly seated.
16. Install the free wheel pin (11) in the sleeve (4) and clutch (5) and insert the assembly into the case (9).
17. With the lock cylinder assembly installed in the case (9), install the retainer (10) and stake the retainer in place using a small punch and hammer to peen the case material onto the exposed ends of the installed retainer (10).
18. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

Lifting and Jacking the Vehicle

Note. The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment.

Scheme 8

Vehicle Lifting- Frame Contact Lift

Note. The hoist pads must not contact the rocker panel moldings or the underbody air deflectors. Additional clearance may be required for the lifting points.

Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads on the rocker outer panel weld flange, as shown

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rocker outer panel weld flange, as shown.

Scheme 9

Note. It may be necessary to put ramps under the Volt's front tires in order to provide necessary clearance for certain service jacks.

Front Service Jack Location

Scheme 10

When lifting the vehicle with a service jack, place the lift pad on the front cradle rear mount bracket, as shown.

Rear Service Jack Location

Scheme 11

When lifting the vehicle with a service jack, place the lift pad on the rear spring support, as shown.