Chevrolet 2011 Volt User manual

1
2011 Chevrolet Volt
GM Service Technical College provides Collision Repair Guides free of charge. Collision Repair Guides can be displayed in
a classroom as long as they are represented as GM information and are not modified in any way.

2
The Chevrolet Volt is a front-wheel drive, four-passenger electric vehicle with extended-range capability. The vehicle
is propelled exclusively by electric motors. The Volt uses high voltage energy that is stored in the high voltage battery
as its primary power source. However, once the battery capacity is reduced, the gasoline engine drives a generator
which produces electricity to power the vehicle.
The intent of this guide is to provide the collision repair technician information to properly handle and repair Chevrolet
Volt vehicles in the safest manner possible. This guide contains a general description of how the Chevrolet Volt vehicle
systems operate, identifies the location of the unique components, fuse blocks, and lifting locations. The guide also
describes methods of disabling the high voltage system and identifies cut zone information.

3
High Strength Steel
The Volt has been designed to protect the
occupant(s) during a collision. The body structure is
nearly 80% high strength steel. The occupant ‘s are
protected from front, rear and side impacts by a
structural cage created by the underlying vehicle
structural design. The following parts are for formed
using ultra high strength steel:
•Door Inner Reinforcement Beams
•Center Pillar Reinforcements
•Windshield Pillar Reinforcements
•Rocker Panel Reinforcements
•Rear Compartment Lower Rails
Additional crumple zones protect the occupant with
front, side and rear rails that are designed to crush in
a crash.

4
Potential damage area to
high voltage components.
The Volt battery has 360 volt
electrical potential at all
times. It is inside the center
tunnel and under the rear
seat area.
Vehicle CUT ZONES Potential damage area to high
voltage components. Side curtain air
bags and lift gate hold open struts.
WARNING: Do NOT cut into the vehicle
until the 12V electrical system has been
disabled. Cutting into the vehicle prior to
disconnecting and isolating the 12V
electrical energy sources may cause air bag
deployment resulting in serious injury.
Use caution when cutting in these areas:
•Center tunnel area or the area under
the rear seats. The 360 volt battery is
installed in this area.
•Roof rails near the lift gate hinge. Side
curtain air bag inflators and lift gate hold
open struts are located in this area
•Front seat back on the outboard area,
contains side air bags.
•B pillar near the rocker, contains the
seat belt retractor pretensioner. Note:
The outboard area of the front seat
lower frame houses an additional seat
belt pretentioner.

5
Welding
When Welding GM recommends
disconnecting the 12volt battery
and removing any modules If
welding with-in 12 inches or
300mm of them. GM also
recommends disabling the high
voltage system if welding with-in
12 inches or 300mm of the high
voltage battery

6
Paint Baking
General Motors does not recommend
baking the Volt vehicle for more then
40 minutes at 140° Fahrenheit or 60 °
Celsius. Damage to the high voltage
battery may occur.

To lift the vehicle on a hoist, use the
rocker outer panel weld flanges in each
corner of the vehicle.
Note: To avoid damage to the
vehicle, the hoist pads MUST not
contact the rocker panel moldings or the
under body air deflectors.
Lifting and Jacking

8
Lifting and Jacking
The Chevrolet Volt may be lifted using a service jack from a single location. To raise the right-front or left-front of the
vehicle, place the service jack pad under the rear mounting bracket of the front cradle. To provide sufficient clearance for
certain service jacks, it may be necessary to place ramps under the vehicle's front tires. To lift the rear of the vehicle,
place the service jack lift pad under the rear spring support.
Rear Lift Points.
Front Lift Points.

9
The Volt is equipped with eight air bags to protect the
occupant in front, rear, side and rollover crashes for
360° of protection.
The Volt is one of the few vehicles with knee air bags
which helps reduce injuries to the front occupant’s
legs.
Chevrolet Volt Air Bags
There are dual pretensioner
seatbelts that work together with
the air bag system to protect the
occupant in the event of a crash.
Seat Mounted Side
Air Bags
Driver and
Passenger Air Bags
Roof Rail
Air Bags
Knee Air Bags

10
The contactors within the high voltage battery are
commanded open whenever one or more airbags
deploy. This interrupts the 360 volt electrical system
and discontinues current flow through the high
voltage cables.
This vehicle is equipped with dual-stage air bags
and the appearance of deployed air bags does not
ensure all stages of the air bags have deployed.
Therefore, disabling 12 volt power is essential to
ensure personal safety even if the airbags in the
vehicle appear to have been deployed. After
disabling 12 volt power, wait 1 minute to allow any
un-deployed air bag reserve energy to dissipate.
Air Bag Deployment