December 2010

Volume 12, No.12

The lectric 2011 Chevrolet Volt

(40 to 80 km), depending on ambient tem-
perature, terrain and driving technique.
When the energy level of the battery
drops below the state-of-charge window,
the Volt seamlessly transitions to ex-
tended-range mode. Power is inverted
from a technically advanced, 1.4L 63-kW
(84-hp) gasoline-powered onboard engine
to the electric drive unit to provide up to
310 additional miles (500 km) of range
on a full tank of fuel. When the car is
plugged in and recharged, it runs again on
a pure electric charge.
The Volt reaches a top speed of 100
mph (160 km/h). The electric drive unit’s
excellent low speed torque of 273 lb.-ft.
(368 Nm) takes it from 0 to 60 mph in less
The all-new 2011 Chevrolet Volt electric vehicle with extended range goes on sale than 9.0 seconds and the quarter mile in
in the U.S. this month. The five-door, four-passenger Volt provides the benefits of an less than 17.0 seconds.
electric vehicle without the range limitations associated with other electric vehicles in continued on page 2
the market.
The extended-range capability of the Volt enables it to be operated when recharging
is not immediately available, such as during a power outage or on a long-distance trip.
PROPULSION SYSTEM
The Volt is a one-of-a-kind, all-electrically driven vehicle engineered to operate in Contents
all climates.
GM’s revolutionary Voltec propulsion system consists of a 16-kWh lithium-ion battery The Electric 2011 Chevrolet Volt . . . . . . . .1
pack and electric drive unit that provide a pure electric range between 25 and 50 miles Component Codes Coming to SPS . . . . . . .1
Module Programming Error E4398 . . . . . .2
Techline News Inspection/Maintenance Test DTCs . . . . . .3
Voltec Electric Drive Unit and
Component Codes Coming to SPS High Voltage Battery . . . . . . . . . . . . . . . .4

A component code is used to assist Volt Engine Operation . . . . . . . . . . . . . . .5

in identifying a common part when the GM Technical Assistance Center
part name appears differently depend-
Offers Dedicated Volt Support . . . . . . . . . .5
ing on publication, such as when the
Service Information (SI) is translated Charging the Volt . . . . . . . . . . . . . . . . . .6
into different languages. A component
Volt Service and Training . . . . . . . . . . . . .7
code is not to be confused with an
RPO code. Service Know-How . . . . . . . . . . . . . . . . .7
Component codes will always be Car Issues – Fix It Right the First Time . . . .8
the same once assigned to a unique
part name. Truck Issues – Fix It Right the First Time . . .9
The control module component code will now
Until recently, component codes be listed in SPS.
were only found in the SI application for
Customer Care and Aftersales
continued on page 2
The Electric 2011 Chevrolet Volt –
Volt 1.4L engine and electric drive unit
Driver-Selectable Drive Modes
The Volt is a one-of-a-kind global
electric car designed to perform in all
climates, and offers performance modes
for varying driving styles and conditions.
Using the Drive Mode button on the
center stack, the driver can choose
Normal, Sport or Mountain Mode:
Drivers can select Normal, Sport or
Mountain Mode drive modes.
Normal Mode: This default setting
provides the most efficiency, whether the
vehicle is powered by electrical energy
that is stored in the propulsion battery or
generated by the range-extending gas
engine.
Sport Mode: Sport Mode automatically
reconfigures the accelerator pedal re-
sponse to provide quicker torque applica-
tion when desired in various driving situa-
tions. While it doesn’t provide a higher full
power output, it does provide more sensi-
tive feedback to driver inputs.
Mountain Mode: Mountain Mode
automatically adjusts the system to
reserve a sufficient state of charge for
driving over mountain passes in ex-
tended-range mode. The driver should
select this mode at least 20 to 25 minutes
before entering mountainous terrain (long
grades of 5% or higher), to enable full
vehicle capability up sustained grades. If
Mountain Mode is selected with a battery
charge of four bars or less on the propul-
sion battery gauge, the engine will run at
a higher speed to build the battery buffer.
If Mountain Mode is not selected in
mountainous terrain, there may be
reduced propulsion power and a higher
engine speed until a normal battery state
of charge can be recovered.
HIGH VOLTAGE BATTERY
The Volt’s high voltage battery consists
of a 5.5-foot, 435-pound (198.1 kg)
T-shaped, 16-kWh lithium-ion battery
pack. It supplies energy to an advanced,
111-kW (149-hp) electric drive unit to pro-
pel the vehicle. The battery pack consists
of nine modules and 288 prismatic cells.
Charging
Charging the Volt’s battery is simple
and intuitive, and can be done through
120V conventional household electrical
Charging Times
240V charging Approximately
station 4 hours
120V household Approximately
outlet 10 hours
continued from page 1
outlets, or through a dedicated 240V
charging station.
Once the vehicle is plugged in, owners
can schedule either immediate or delayed
charges, even coordinating charging
according to departure time or when elec-
tricity rates are lower. Owners also can
manage and monitor the Volt remotely via
computer on MyVolt.com; or with the
OnStar MyLink smart phone application.
CHASSIS
Volt is equipped with standard chassis
control systems such as ABS, traction
control and StabiliTrak electronic stability
control. An isolated four-mount front
cradle contributes to the Volt’s overall
quietness, outstanding noise and vibration
performance, and ride and handling
dynamics.
Components of the Volt’s MacPherson
strut-type suspension are constructed of
forged aluminum for reduced weight.
The compact Volt chassis includes the
T-shaped, 16-kWh lithium-ion battery pack
between the rear wheels.
Cold-formed, high-performance front
springs are lighter and use less coiling
than conventional springs.
A sophisticated compound crank rear
axle provides quick reaction, low weight
and consistent camber control. The cast
iron control arms are attached to the steel
cross-car beam with a patented magnetic-
arc welding process.
continued on page 3

Component Codes – Module Programming

continued from page 1
schematics, diagnostic procedures and support information.
Refer to August 2009 TechLink for additional information related
to component codes in SI.
Component codes will now be referenced in the Service
Programming System (SPS) for Global A models (Camaro, Cruze,
Equinox, Terrain, SRX, LaCrosse and Regal) to help provide
consistency in identifying programmable control modules with
their reference in SI.
The component code will be listed along with the global abbre-
viation and control module long name. Some examples include:
• K9 – BCM Body Control Module
• K17 – EBCM Electronic Brake Control Module
• K20 – ECM Engine Control Module
• K36 – SDM Sensing and Diagnostic Module
• K71 – TCM Transmission Control Module
– Thanks to Mike Waszczenko and Lisa Scott
2 December 2010
Error E4398
When reprogramming an existing module or programming a
new module on 2011 and prior GM passenger cars and light-
duty trucks, do not replace the module if an E4398 error code
occurs during the programming process.
TIP: An E4398 programming error code could occur while
programming any module (i.e. BCM, ECM, PCM, TCM,
EBCM, etc.)
An E4398 programming error is the result of a missing or
incomplete data record. This error is not related to the module
being programmed or a vehicle issue. It can be repaired by
obtaining a Vehicle Configuration Index (VCI) number from the
Techline Customer Support Center (TCSC).
DO NOT replace the module. Call TCSC at 1-800-828-6860,
prompt #2, (English) or 1-800-503-3222 (French) for a VCI num-
ber, which will allow the module to be programmed correctly.
– Thanks to Ray Romeo
Electric Power Steering
The Volt features a ZF variable assist
electric power steering system with dual
pinions (one is used for steering, the
other to add assist). A combined electric
motor and sensing unit monitors steering
angle, and delivers appropriate assist to
the steering gear in all conditions. The
system draws its power from a 12V
battery in the rear of the vehicle.
Regenerative Braking
The Volt's fully blended electro-
hydraulic brake system enables 100%
regenerative braking, 100% traditional
disc friction braking, or any combination
of both.
Regenerative braking, which captures
energy for transfer back to the battery,
can provide up to 0.2g of deceleration
(about 94% of braking events). Braking
that involves more than 0.2g of decelera-
tion is a combination of regenerative and
friction braking. During a panic stop, the
system seamlessly transitions to 100%
friction.
TIP: If the battery is fully charged, the
brake controller directs the system to
conduct friction braking.
The disc brake system uses a high-
pressure hydraulic accumulator to provide
boosted braking.
Lightweight aluminum wheels weigh
only 17.8 pounds (8.1 kg) each, compared
to 24.2 pounds (11 kg) for typical 17-inch
wheels. Goodyear Fuel Max all-season
low-rolling resistance tires are optimized
for electric vehicle range, noise, feel and
performance.
The Volt is equipped with an electric
parking brake, which is applied by pulling
the Parking Brake switch next to the shift
lever. To release the parking brake, with
the ignition monitor and control vehicle functions
ON, press the remotely — redefine how owners will
brake pedal interface with the vehicle.
and press the Key technologies include:
Parking Brake
• High-resolution, seven-inch, full-color
switch.
LCD reconfigurable Driver Informa-
Safety fea- tion Center display and instrument
tures on the cluster. The display shows electric-
Volt include only range, fuel economy, extended-
eight airbags range, trip information, tire pressure
and advanced information and a variety of vehicle
LED daytime messages.
running lamps.
• High-resolution, seven-inch, full-
The Passenger
Volt features lightweight color, center stack-mounted touch
Presence
aluminum wheels and low- screen display that serves as the
System in the
rolling resistance tires. interface for infotainment and cabin
front passen-
climate controls. An Efficiency (Leaf)
ger seat is a
button accesses power flow, charg-
capacitive system and will detect any
ing, and energy information screens.
electronic devices (laptop computer, cell
phone, etc.) sitting on the front seat. • Touch-control infotainment and
Remove these items to turn off the climate control systems on the
PASSENGER AIRBAG ON light when center stack.
the seat is unoccupied. • Charge modes that are customizable
according to need and electricity
Volt Technology rates for efficient programming and
There is much more technology inside lower costs.
the Volt than its electric propulsion sys-
• Remote Keyless Entry that allows
tem. Intuitive features — high-resolution drivers to remotely start the vehicle
displays, connectivity and the ability to and precondition the cabin based on
outside temperatures while the
vehicle is plugged in, enhancing
efficiency.
• An exclusive mobile app, powered
by OnStar MyLink, which enables
owners to engage with Volt
functions such as checking battery
charge level, initiate charging, and
lock/unlock the doors using a smart
phone.
– Thanks to Keith Newbury and
Volt packs technology in the Steve Falko
passenger cabin too.

Inspection/Maintenance Test DTCs

After repairs on any On-Board Diagnostic (OBD) II-related
systems, technicians may find that any Inspection/Maintenance
(I/M) Test DTCs that are stored will not clear.
I/M Test DTCs are different than traditional current and history
DTCs and are used in certain State/Province vehicle emission
test programs. The rollout of I/M Test DTCs began in the 2010
model year and will be completed by the 2013 model year. Vehi-
cle implementation is by model and engine, so not all models will
be updated at the same time, depending on engine option.
I/M Test DTCs cannot be cleared using a scan tool or by
disconnecting power to the control module. They will only clear
when the control module diagnostic that set the DTC has run and
passed, confirming the problem has been repaired. Some
diagnostics for I/M Test DTCs will run and pass very quickly (a
repaired open circuit DTC will pass in milliseconds), while others
may take days depending on vehicle operating conditions (such
as a complex diagnostic for an EVAP small leak test).Stored I/M
Test DTCs discovered during a vehicle emission inspection may
cause a vehicle to fail or be rejected.
Using a scan tool, technicians can observe I/M System Status.
The display provides an indication of when the control module
has completed the required tests. This does not necessarily
mean that the test has passed, only that a decision was made.
If the diagnostic fails, a traditional DTC will indicate the failure.
The I/M System Status information may be useful for a techni-
cian to determine if diagnostics have run when verifying repairs.
The traditional current and history DTCs still exist exactly as
before and can be cleared using a scan tool. Every Service
Information (SI) diagnostic procedure that indicates to clear
codes should be followed, and the Malfunction Indicator Lamp
(MIL) should not illuminate if the problem is not present.
– Thanks to Jack Woodward

December 2010 3
Voltec Electric Drive Unit and High Voltage Battery
The innovative Voltec electric propulsion system combines a
16-kWh lithium-ion battery pack with a 111-kW (149-hp) electric
drive unit. The electric drive unit powers the wheels at all times.
DRIVE UNIT
Most battery electric vehicles use a single motor with a fixed
reduction gear that steps down the motor speed to synchronize
with the wheel speed.
The Chevrolet Volt uses a unique electric drive unit to boost
efficiency. The efficiency of any electric motor always drops off
as it approaches its maximum rotational speed. The Volt drive
unit consists of two electric motors, three clutches and a plane-
tary gear set that improve overall efficiency by reducing the
combined rotational speed of the electric motors. This configura-
tion reduces battery drain at highway speeds, adding up to two
miles of additional EV range.
Electric drive unit
The Volt’s motors and gear-set are mounted in-line with the
industry’s first range-extending internal combustion gasoline
engine. Two of the clutches are used to either lock the ring gear
of the planetary gear-set or connect it to the generator/motor,
depending on the mode. The third clutch connects the gasoline
engine to the generator/motor to provide range extension
capability.
This innovative new drive unit has four distinct operating
modes.
Electric Vehicle Modes
Electric Only, Engine Off (One Motor) – The vehicle operates
in full-electric mode without starting the engine for approximately
25 to 50 miles (40 to 80 km), depending on ambient tempera-
ture, terrain and driving technique. The primary traction motor
provides all propulsion, drawing all of its energy from the battery.
Electric Only, Engine Off (Two Motors) – During highway
cruising, if the required torque to propel the vehicle is low, the
ring gear is coupled to the generator/motor. This allows the two
motors to work in tandem for greater efficiency.
Extended-Range Modes
Electric Only, Engine On (Series) – Once the battery has
reached a determined state of charge, the gasoline engine will
start. It is coupled to the motor/generator via the third clutch. The
engine-driven generator and battery provides electricity to the
4 December 2010
traction motor via the inverter. The engine will operate at an
appropriate speed to optimize fuel consumption while maintain-
ing output power requirements.
Because the most efficient way to charge the Volt’s battery is
to plug it in, the generator is used only to maintain minimum
battery state of charge. If the battery is drawn down below the
minimum level, the generator will charge the battery up to its
minimum state of charge and then maintain it there.
Output Split, Engine On (Combined) – The blended two
motor electric propulsion strategy used at higher speeds in EV
driving also has been adapted for extended-range driving. During
highway cruising, if the required torque to propel the vehicle is
low, the clutches that connect the generator/motor to both the
engine and the ring gear are engaged, combining the engine and
both motors for efficient operation in an output power split
configuration.
TIP: Under no circumstances can the Volt be dinghy towed.
Towing is to be done by a flatbed carrier only.
HIGH VOLTAGE BATTERY
The Volt is powered by a lithium-ion high voltage battery pack,
which holds its charge efficiently and has no memory effect
(so it doesn’t have to be run down completely before recharg-
ing). The owner should keep the vehicle plugged in, even when
fully charged, to keep the battery temperature ready for the
next drive.
Lithium-ion was chosen over nickel metal hydride for the Volt
battery because it packs two to three times the power of a nickel
metal hydride battery in a much smaller package. It also is more
efficient and suffers little loss of charge when not in use.
The battery pack is liquid cooled, T-shaped, and located
beneath the vehicle. The 360V direct current battery is formed
from 288 cells. Each cell is 5 x 7 x 1/4 inch, and weighs about a
pound. Cells are grouped together to form distinct blocks,
referred to as sections.
The battery is connected to the propulsion circuit or charging
circuit using unique pairs of contactors. In general terms, the
main contactors will close when the ignition switch is in the ON
position, and the charging contactors will close when plugged in
with the ignition
switch in the OFF
position.
The high volt-
age battery is
also connected
to two distinct
low voltage “high
voltage interlock”
(HVIL) circuits,
one for propul-
sion, and one
for charging.
Because
batteries can be
sensitive to tem-
perature changes, Lithium-ion high voltage battery pack
the Volt pack is
climate-controlled
via an exclusive active liquid control system that continually
monitors and maintains the battery pack temperature for opti-
mum performance and durability. Circulating liquid (consisting of
coolant and distilled water) passes through a series of internal
heat exchangers in the battery modules. It is designed to provide
reliable battery operation when plugged in, at temperatures as
continued on page 5
Volt Engine Operation
The range-extending Ecotec 1.4L I-4 VVT gasoline engine (RPO The 300V drive motor/generator can rotate the engine to operat-
LUU) features a number of unique systems that may operate in ing speed (800 rpm) within just a few hundred milliseconds.
unfamiliar ways to Volt owners. The 300V drive motor/generator allows near-instant starting of
the engine.
Conditions that Cause the Gasoline Engine
to Start Filling the Fuel Tank
Independent of The Volt is equipped with a pressurized fuel system that is
the vehicle being sealed from the atmosphere when the gasoline engine is not op-
plugged in or erating. Refueling can occur only after the fuel system has been
completely adequately vented to atmosphere through the carbon canister.
charged, when Premium fuel with an octane rating of 91 or higher is required.
vehicle power is Owners who do not understand the fuel door operation may
ON, the gasoline believe the door has malfunctioned.
engine may start 1. Press the Fuel door release button, located on the driver’s
under the follow- door, for one second. The Wait to Refuel message will
ing conditions: display on the instrument cluster.
• Propulsion 2. When the Ready to Refuel message displays, the fuel door
battery on the passenger’s side of the vehicle will unlock. It will not
charge is low open automatically.
• Propulsion 3. Press the rear edge of the fuel door; it will pop open
battery tem- slightly. Open the door to refuel the vehicle.
perature is Ecotec 1.4L I-4 VVT gasoline engine
hot or cold (RPO LUU) Maintenance Modes
• Cold ambient The Engine Maintenance Mode will run the engine to keep it in
temperatures less than approximately 25° F (4° C) good working condition after approximately six weeks of no or
very limited engine operation.
Starting the Engine
The Fuel Maintenance Mode tracks fuel age and will run the
This vehicle does not use a 12V starter motor to crank the engine to use the fuel if the average fuel age exceeds approxi-
gasoline engine. A much more powerful 300V motor/generator mately one year.
located within the transmission is utilized to crank the engine.
– Thanks to Keith Newbury and Steve Falko

Voltec GM Technical Assistance Center

Electric
Drive Unit –
cont. from page 4
low as -13° F (-25° C) and
as high as 122° F (+50° C),
and can be powered during
driving either by the battery
or the engine.
Fully charging or fully
depleting a battery shortens
its life. The Volt battery is
controlled, or buffered, so
it operates within a safe
state-of-charge window. In
demanding situations (such
as driving in Mountain mode),
the battery state of charge
will raise the lower limit to
ensure there is adequate
power when needed. The
battery’s top and bottom
buffer zones help ensure
long life.
– Thanks to Keith Newbury
and Steve Falko
Offers Dedicated Volt Support
The GM Technical Assistance Center (TAC) in
the U.S. is ready to provide outstanding service
support to Chevrolet Volt certified service
technicians on all Volt issues and repairs.
The entire GM team has been working
together to ensure that the people, processes,
and equipment are in place to deliver excep-
tional technical support and service. The process
begins with you, the Volt certified service techni-
cian, working with the GM TAC team to report
and solve vehicle concerns.
Special Support Model
A special team of TAC representatives with a
deep understanding of the Chevrolet Volt has
been created to allow greater flexibility to serve
technicians. Beginning in mid-December, this
dedicated team will be available to provide fast,
accurate diagnostic and repair direction to TAC
callers. Each member of this team has been
through extensive training alongside the Field
Service Engineers.
In addition, a Volt will always be at the TAC so
that the dedicated team will have direct hands-
on access to a vehicle when needed. Plus, the
team will have direct contact with Volt engineers
to verify diagnostic paths, component testing
procedures and review other service issues.
Extended Hours
In order to support Volt service techni-
cians — and, in turn, Volt customers — the
TAC dedicated Volt team will be available
on Saturdays to assist with Volt cases
beginning December 4, 2010, from 8:00
AM to 8:00 PM Eastern time, in addition
to normal TAC business hours.
How You Can Help
What can you do to support efforts to
provide exceptional service? Please call in
to report ANY issues on a Chevrolet Volt.
All Volt cases will be in the hands of the
Volt Engineering Team immediately. Please
call early in the diagnostic process in order
to receive the necessary service support.
The Volt team understands that this vehi-
cle technology is new to everyone and that
we need to work together!
Our dedicated team is ready to assist
you in helping provide Volt customers with
an outstanding service experience with
their truly exceptional vehicle.
– Thanks to Steve Oakley

December 2010 5
Charging the Volt
Once the initial Charging Status
electric charge is The charging status indicator is located on the instrument
depleted, the range- panel near the windshield.
extending gasoline
engine will start to TIP: Immediately after plugging in, the charging status indicator
generate enough may be amber for up to five seconds before turning green. The
power to continue charging system may run fans and pumps when the vehicle is
driving the vehicle. turned off.
The engine driven
generator will not Charging Status Indicator Condition
fully charge the
Solid green with single horn chirp Vehicle is plugged in; battery is charging
propulsion battery
pack in the Volt.
Slow (long pulse) flashing green Vehicle is plugged in; delayed battery
The vehicle must with double horn chirp charging
be plugged in to The Volt includes a 120-volt portable
recharge. charge cord.
Vehicle is plugged in; battery is fully
Fast (short pulse) flashing green
Plug-In Charging charged
The provided 120-volt portable charge cord is located in the
Solid yellow Vehicle is plugged in; not charging
storage compartment under the cargo floor. To charge the
vehicle:
Vehicle is not plugged in OR there is an
1. Plug the charge cord into an electrical outlet. All four charge No light
issue with the charger or wall outlet
level indicators should be green.
TIP: Do not use an extension cord. Electricity was interrupted before charging
Horn chirps and no light
TIP: A reduced charging level is available on the portable was completed
charge cord when the electrical current is limited by pressing the
orange charge level button. Only two charge level indicators will Using a standard
illuminate. 120-volt household
2. Press the Charge port door release button, located on the outlet, it will take ap-
driver’s door or RKE transmitter, for one second. proximately 10 hours
3. Plug the charge cord into the vehicle’s charge port located to charge the Volt, and
in front of the driver’s door. using a 240-volt
charging station will
TIP: Squeeze the plug button on the charge cord to use the take approximately
flashlight to help illuminate the charge port if needed. four hours to charge.
4. The charging indicator on top of the instrument panel will
illuminate green and the horn will chirp when properly Charging Modes
connected. If the vehicle is locked with the RKE transmitter, Press the Leaf When the battery is being charged, the
the charge cord theft alert is armed automatically after button and then touch status indicator will be solid green.
30 seconds. the Charging tab on
TIP: When the theft alert is armed, the alarm will sound when the center stack touch
the plug is disconnected from the locked vehicle. screen or press the Charge port door release button to view the
current charge mode status.
Charge Cord Status lt can be programmed for three charging modes:
The charge cord status indicators illuminate green or flashing • Immediate: Starts charging as soon as it is connected to an
red to identify the charge cord status. If any indicators are flash- electrical outlet
ing red, the charge cord will not permit vehicle charging.
• Delayed Departure Time: Calculates the
charging start time and completion based on
Charge Cord Status Indicator Condition the schedule entered
• Delayed Rate and Departure Time:
Calculates the charging start time based on
Flashing red AC PRES- utility rate schedules, rate preference and
AC voltage is out of range
ENT (A) the programmed departure time for the
current day of the week
End Charging
1. Unlock the vehicle with the RKE transmitter
Flashing red AC PRES- to disarm the charge cord theft alert.
AC outlet does not have a proper safety ground
ENT (A) and FAULT (B)
2. Unplug the charge cord from the vehicle by
squeezing the plug button.
3. Unplug the charge cord from the electrical
Charge cord fault. The charge cord will attempt outlet.
to reset automatically. If the fault continues for
Flashing red FAULT (B) more than 30 seconds, unplug the charge cord 4. Stow the charge cord.
from the wall to reset. If the fault remains, the – Thanks to Keith Newbury and Steve Falko
cord requires service.

6 December 2010

GM TechLink is a monthly magazine
for all GM retail technicians and
service consultants providing timely
information to help increase know-
ledge about GM products and
improve the performance of the
service department.
Publisher:
Thomas J. Arnold
GM Customer Care and Aftersales
/ Thomas.Arnold@GM.com
Editor:
Lisa G. Scott
GM Customer Care and Aftersales
/ Lisa.G.Scott@GM.com
Technical Editor:
Mark Spencer
/ mspencer@gpworldwide.com
Production Manager:
Marie Meredith
Desktop Publishing:
5by5 Design LLC
/ dkelly@5by5dzign.com
FAX number: 3 VPTVT.010W3
1-248-729-4704
Write to: *
TechLink
PO Box 500
Troy, MI 48007-0500
GM TechLink on the Web: : 18420.02W
GM GlobalConnect
General Motors service tips are
intended for use by professional
technicians, not a “do-it-yourselfer.”
They are written to inform those
technicians of conditions that may
occur on some vehicles, or to provide
information that could assist in the
proper service of a vehicle. Properly
trained technicians have the
equipment, tools, safety instructions
and know-how to do a job properly and
safely. If a condition is described, do
not assume that the bulletin applies to
your vehicle or that your vehicle
will have that condition. See a General
Motors dealer servicing your brand of
General Motors vehicle for information
on whether your vehicle may benefit
from the information.
Inclusion in this publication is not
necessarily an endorsement of the
individual or the company.
Copyright© 2010 General Motors Company
All rights reserved.
December 2010
Volt Service and Training
Working on the electrical systems of the Volt requires following all safety precau-
tions. This means having the proper equipment as well as using it in a safe manner.
Safe Multimeter Practices
Multimeter safety standards must be followed to help ensure safe work practices.
Make sure your multimeter meets the latest International Electrotechnical Commis-
sion (IEC) safety standards for test equipment and that it is in good condition.
For more information about safe multimeter practices when working on high
voltage electrical systems, refer to the January 2008 edition of TechLink.
Hand Tools
TIP: Volt training mandates that the high voltage system be disabled BEFORE
performing any repairs.
Insulated class 0 isolation gloves (leather outside, rubber inside) are required during
service. The class 0 gloves are rated up to 1000 volts. Also follow all the appropriate
safety precautions outlined in SI.
In addition, technicians may choose to purchase insulated hand tools. A variety of
tools are available from several tool manufacturers.
Training
To learn more about the features of the Volt and key safety and service features,
refer to the Volt training courses available on www.gmtraining.com. (In Canada, due
to the later introduction of the Volt, training will begin in the second quarter of 2011.
Visit www.gmprocanada.com for details.)
Course Number Course Name Delivery Method
Service Consultant Training
VPTVT.010W1 Volt Service Overview Web
VPTVT.010W2 Volt Maintenance 101 Web
Volt Battery and Charging 101 Web
VPTVT.010W4 Volt Service Experience 101 Web
Technical Training
18420.01W Volt Introduction and Safety Web
High Voltage Energy Storage Systems Web
18420.03W Advanced Technology Vehicle Power Electronics Web
18420.04W Advanced Technology Vehicle Transmission Web
18420.05W Advanced Vehicle Technology Supporting Systems Web
18420.02T1 Volt High Voltage Disable Procedure Web
18420.06D1 Electric Vehicle Systems Diagnosis and Service Session 1 Web
18420.06D2 Electric Vehicle Systems Diagnosis and Service Session 2 Web
18446.01H Two-mode Hybrid Safety and Battery System Service Hands-on
10210.12D Emerging Issues December 9, 2010
To view Emerging Issues seminars:
Service
Log in to www.gmtraining.com, select Service Know-
Know-How How/TECHAssist from the menu, select Emerging Issues,
and then Searchable Streaming Video to choose the current
Emerging Issues seminar or past programs.
7
 Car Issues – Fix It Right the First Time
Model Year(s) Vehicle Line(s) / Condition
2004-2011 AURA, G6, Malibu, Malibu Maxx –
Intermittently brake lights (stop
lamps) do not function correctly,
cruise control inoperative
2004-2011 CTS, SRX, STS – Information to
prevent incorrect installation of air
cleaner cover to air cleaner
housing
2009-2011 HHR, Impala – Front passenger
heated seat insufficient heat and
proper system operation
2008-2009 G8 – Automatic transmission 6th
gear whine
2009-2011 Acadia, AURA, Enclave, Envoy, G5,
G6, H2, H3, OUTLOOK, Sierra, SKY,
Solstice, Suburban, Tahoe, Terrain,
Torrent, VUE, Yukon – Buzz noise
during call when using Bluetooth
2009-2011 Corvette – Visor-mounted garage
door opener will not
program/universal home remote
system does not operate garage
door
2010-2011 LaCrosse – Power steering system
moan or metal grind noise when
turning steering wheel
2010 Malibu – Engine surge during high
ambient temperatures
2010 Impala – No crank/no start,
solenoid clicks
2007-2011 Impala, Malibu – Sunroof sunshade
cloth comes loose from sunshade
panel
2010 Cobalt, G5 – Increased rear
compartment lid closing effort,
trunk ajar displayed in DIC with
trunk closed, poor rear
compartment lid fit/alignment
2011 Cruze – License plate will not fit in
front bracket during Pre-Delivery
Inspection (PDI) process
2010-2011 Camaro – Front seat cushion cover
J-channel retainer comes loose
from front of seat frame
2010-2011 Camaro, SKY, Solstice – Radio
display screen scratches
2007-2010 AURA, Malibu, VUE – Check Engine
light illuminated, DTC P0AA1 set
2010 Equinox, LaCrosse, SRX, Terrain –
Engine oil leak from oil pan at
mounting area
2010-2011 SRX – MIL-Check Engine light on,
DTC P182E Set
Do This Don’t Do This Reference
Information / Bulletin
Disconnect the C2 or X2 connector, Replace BCM 08-05-22-009C
Add dielectric lubricant and
reconnect the connector
Always make sure air box is Completely remove from the housing 08-06-01-020A
assembled correctly the (outlet side) cover if just
replacing the filter element
Compare performance to the Replace the heater element 09-08-50-013A
passenger seat in a like car to see if
seat heater is normal
Install new transmission mount Replace any other front suspension 10-07-30-012
parts
Ensure that the customer's phone is Perform this microphone 10-08-44-003B
an older GSM type, and the noise is replacement for newer phones that
heard on the land-line side only do not use GSM
before attempting the microphone
replacement
Reset the garage door opener first Replace the visor/garage door opener 10-08-97-001
and then contact the toll-free
number for assistance with
programming the garage door
opener
Replace steering gear and I shaft Replace the power steering pump or PI0172A
with new part and install new hose
calibration
Install new calibration Replace parts for this issue PI0245
Check battery cable ground Replace starter PI0249
connection
Re-glue the sunroof sunshade cloth Replace the sunroof sunshade PI0250A
to the sunshade panel
Adjust decklid Replace the latch PI0252
Inform the customer a fix is under Replace the radio or faceplate PI0254
development
Cut the j-clip on the seat cover and Replace the seat cover PI0258
reinstall the cover
Polish the radio faceplate screen Replace the radio faceplate 09-08-44-015C
Replace battery energy control Replace battery energy control 10-06-130-002A
module wiring harness module
Clean bolt hole with brake cleaner, Replace oil pan PI0263
air dry and apply thread locker to
bolt threads
Make sure to pull back firmly on the Replace the switch without verifying PI0231A
shifter when adjusting the shift the cable adjustment
cable
8 December 2010
 Truck Issues – Fix It Right the First Time

Model Year(s) Vehicle Line(s) / Condition Do This Don’t Do This Reference

Information / Bulletin

2010-2011 Acadia, Avalanche, CTS, CTS-V, CTS Sport Wagon, Reprogram the rear object sensor Replace the rear object sensor PI0267
CTS-V Sport Wagon, Enclave, Escalade, Escalade control module control module or rear.
ESV, Escalade EXT, Sierra, Silverado, Suburban,
Tahoe, Traverse, Yukon, Yukon Denali, Yukon XL,
Yukon XL Denali – Park Assist blocked, See Owners
Manual message repeatedly on DIC

2008 Acadia, Enclave, OUTLOOK – SIR light on, DTC Replace connector between seat- Grease the existing connector or 08-09-41-011C
B0014 and B0021 set in SDM mounted side impact airbag and replace the harness
body harness, reroute harness

2007-2010 Acadia, Enclave, OUTLOOK, Traverse – Whine/moan Perform a thorough bleed of the Replace the power steering 10-02-32-002
noise from power steering system during low speed system pump before performing the
maneuver bleed procedure in the bulletin

2007-2010 Allure, Avalanche, Camaro, Envoy, Escalade, G8, Check oil level and fill if low before Use this bulletin on NON AFM 10-06-01-007A
Grand Prix, Impala, LaCrosse, Monte Carlo, Rainier, doing any repairs engines
SAAB 9-7X, Sierra, Silverado, Suburban, Tahoe,
TrailBlazer, Yukon – AFM engine, valve tick noise at
start up when engine has been off for 2 hours or
more

20087-2011 Avalanche, Escalade, Escalade ESV, Escalade EXT, Reposition the locking tabs Replace the air bag assembly 08-09-41-005A
Sierra, Silhouette, Suburban, Yukon, Yukon Denali,
Yukon XL, Yukon XL Denali – Passenger-side airbag
door not flush with dash pad/warped

2000-2010 Avalanche, Blazer, Bravada, Escalade, Escalade ESV, Replace the leaking pitman shaft Replace the entire gear 10-02-33-001A
Escalade EXT, Express, H2, Jimmy, Rainier, S-10, seal
Savana, Sierra, Silverado, Sonoma, Suburban,
Tahoe, Yukon, Yukon Denali, Yukon XL, Yukon XL
Denali – Information on pitman arm shaft seal
service kit

2011 Equinox, Terrain – Interior headliner sagging at dome Re-glue the magnets Replace the headliner PI0253A
lamp area

2006-2011 Canyon, Colorado – Broken front floor console Replace only the center console lid Replace the console lid and/or PI0262
compartment lid/armrest latch latch. Labor operation C9952 armrest assembly. Labor
operations C2740 or C2860

2005-2010 All Vehicles – Reporting missing or inaccurate Ask the customer to report Replace parts 10-08-44-006
navigation radio map disc information- concerns to the GM Navigation
complete/submit Disc Center at:
www.gmnavdisc.com

2011 Sierra, Silverado – Fuel tank slow or difficult to fill Check for kinked vent hose Replace fuel filler pipe or tank PI0261

2007-2010 Avalanche, Escalade, Escalade ESV, Escalade EXT, Correct terminal tension and Replace memory seat module, 10-08-50-008A
Sierra, Silverado, Suburban, Tahoe, Yukon, Yukon reroute harness thermo-electric device (TED), or
Denali, Yukon XL, Yukon XL Denali – Driver or element
passenger heated seat inoperative, slow to warm

2007-2010 Avalanche, Escalade, Escalade ESV, Escalade EXT, Install 3M™ Automotive Acrylic Replace the seat cover 08-08-50-001B
Sierra, Silverado, Suburban, Tahoe, Yukon, Yukon Plus attachment tape to the seat
Denali, Yukon XL, Yukon XL Denali – Front seat frame
cushion cover becomes detached

2010-2011 Sierra, Silverado – Body mount bolt stripped or will Create access hole to repair Use unapproved running boards 10-08-61-001
not loosen that attach to body mounts

2011 Sierra, Silverado – Squeal noise from front of truck / Lube front axle seals Replace axle seals PI0257
independent of brake apply

2007-2011 Sierra, Silverado – Mounting points for pickup box Mount accessories in correct Overload or use cargo 09-08-66-011A
accessories location with acceptable loads management point for
attachment

2011 Sierra, Silverado – Diesel Exhaust Fluid (DEF) filling Add only 3.5 gallons of DEF at PDI Overfill 10-06-04-013
instructions and general information

2010 Acadia, Enclave, Terrain – Whine noise heard when Verify concern occurs only when Replace the radio or VCIM for 10-08-44-005
using OnStar or Bluetooth (install noise filter) using OnStar or Bluetooth feature. this concern
Obtain the filter and install per
instructions

2007-2009 Escalade, Escalade ESV, Escalade EXT Avalanche, Install AFM oil deflector and clean Perform repairs without doing an 10-06-01-008A
Silverado 1500, Suburban, Tahoe Sierra 1500, Sierra carbon from cylinder oil consumption test first
Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali
XL, G8 GT – Engine oil consumption on aluminum
block engines with Active Fuel Management (AFM)

2007-2011 Acadia, Enclave, OUTLOOK, Traverse – Front driver Replace the motor drive cable Replace the seat adjuster 07-08-50-013A
power seat inoperative, driver seat will not move assembly
forward/backward

December 2010 9
Customer Care and Aftersales