Chevrolet 2011 Volt Collision Awareness Manual
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Summary of Contents for Chevrolet 2011 Volt
- Page 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.
- Page 2 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.
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Page 3: High Strength Steel
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. - Page 4 Potential damage area to high Vehicle CUT ZONES voltage components. Side curtain air bags and lift gate hold open struts. 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.
- Page 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...
- Page 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.
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Page 7: Lifting And Jacking
Lifting and Jacking 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. - Page 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.
- Page 9 Chevrolet Volt Air Bags Roof Rail Air Bags Driver and Passenger Air Bags 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...
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Page 10: Air Bag Deployment
Air Bag Deployment 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. - Page 11 SIR Sensor Locations...
- Page 12 SIR Sensor Locations (cont.) 1. Right Front Impact Sensor--Located under the hood at the front right side of the vehicle 2. Passenger Instrument Panel Air Bag--Located at the top right under the instrument panel 3. Right Roof Rail Air Bag--Located under the headliner, extending from the passenger front pillar to the passenger rear pillar 4.
- Page 13 Air Bag Repairs and Inspections Required After a Collision Warning: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than intended.
- Page 14 Air Bag Repairs and Inspections Required After a Collision (cont.) After a frontal collision involving air bag deployment, replace the following components. • Passenger instrument panel air bag, if deployed • Driver steering wheel air bag • Inflatable restraint sensing and diagnostic module (SDM) •...
- Page 15 Air Bag Repairs and Inspections Required After a Collision (cont.) After a collision involving driver/passenger side seat air bag deployment, replace the following components. • Left/right side impact sensors on the side of the impact. • Left/right roof rail air bag on the side of the impact. •...
- Page 16 Break away Pedals If a crash is severe enough to damage the dash panel or distort it, it may cause the pedal assembly to disengage. If this occurs the petal assembly would have to be replaced. DeLatcher DeLatcher Inner & Outer Pedal Arm Assemblies...
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Page 17: System Components
System Components The Chevrolet Volt propulsion system is composed of the following components and systems: • High voltage battery • Absorbent Glass Mat (AGM) low voltage battery (12V) • Power inverter module • Accessory power module • High voltage battery charger •... - Page 18 High Voltage Battery The Chevrolet Volt’s low voltage system (12V) utilizes an AGM lead acid battery. The battery is located in the rear compartment underneath the load floor. The low voltage energy is utilized by vehicle modules to control the high voltage battery contactors.
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Page 19: Power Electronics
Power Electronics The power inverter module is located on the drivers side of the engine compartment and is mounted on top of the transmission. The module changes the high voltage direct current into 3 phase alternating current. This 3- phase electrical energy is provided to the motors within the transmission for vehicle propulsion. -
Page 20: Charging System
Charging System The Chevrolet Volt features an onboard high voltage charging system that recharges the high voltage battery. The system utilizes a unique cord to connect the vehicle to an electrical receptacle. The charger is located behind the passenger headlamp assembly and bumper fascia. The charger converts household AC into DC voltage to charge the onboard battery. -
Page 21: Power Train
• Propel the vehicle • Generate / recapture energy • Start the internal combustion engine 4ET50 Transmission The Chevrolet Volt uses an internal combustion 1.4L engine. The engine does not directly propel the vehicle, but operates only to spin the drive motor / generator. - Page 22 Thermal Management Systems The Vehicle utilizes three separate cooling systems that maintain the proper operating temperature of the components. The components include the drive motor battery, drive motor / generator power inverter module, drive motor battery charger, and engine. The cooling systems require a pre-mixed 50/50 solution of DEX-COOL®...
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Page 23: System Operation
System Operation There are two separate electrical systems, low voltage and high voltage. The low voltage system is similar to a conventional vehicle. The high voltage electrical system distributes 360 volts Direct Current (DC) between the high voltage components and 3-phase Alternating Current (AC) to the transmission. - Page 24 Fuse Block Locations Left and Right Instrument Panel Under hood Rear body fuse Block Battery fuse Block...
- Page 25 Battery Fuse Block The battery fuse block supplies power through the high current fuses to the four electrical fuse blocks which include the underhood, rear body, and left and right instrument panels. The fuse block also connects to the accessory direct current power control module through a 200-amp fuse.
- Page 26 Underhood The underhood electrical fuse block supplies fused low voltage electrical power to common non-hybrid underhood components, such as the Engine Control Module (ECM). The fuse block also supplies 12 volt power to hybrid components, such as the drive motor / generator power inverter module, Hybrid Powertrain Control Module 2 (HPCM 2), drive motor battery, and thermal management components.
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Page 27: Rear Body
Rear Body The rear body fuse block supplies vehicle components, such as the rear defogger, rear hatch release, and fuel pump. The fuse block is located in the left rear quarter panel area. - Page 28 Left and Right Instrument Panel The left and right instrument panel fuse blocks supply power to components, such as the body control module, instrument panel cluster, radio, and 12 volt power receptacle. The fuse blocks are located on the left and right side of the instrument panel behind the trim access door.
- Page 29 The Chevrolet Volt features two dedicated and separate circuits, the main HVIC and the charger HVIC. The main HVIC monitors the primary high voltage components...
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Page 30: High Voltage Cables
The high voltage cables in the Chevrolet Volt are highly protected and should not be cut . However, performing the disabling procedure prior to work eliminates electrical current flow through the 12 volt system and disables the high voltage electrical system, external to the 360V battery. - Page 31 Drive Motor / Generator 3-phase cables 3-Phase Cables There is a set of 3-phase high voltage high current cables connected to each drive motor / generator within the transmission. Each of the cables connects one of the AC phases, U, V, or W to the drive motor coils.
- Page 32 Direct Current Cables High voltage positive and negative DC cables are isolated from the vehicle’s chassis ground. The cables carry high voltage between the drive motor battery, drive motor / generator power inverter module, accessory direct current power control module, heater coolant heater, AC compressor, and the vehicle’s high voltage charging system.
- Page 33 HPCM 2 The HPCM 2 provides the main and charger circuits with 5 volts and ground. The module monitors each circuit for continuity.
- Page 34 HVIC Connectors The HVIC connectors are stacked on each high voltage connector. It is not possible to disconnect the high voltage cable connector before removing the HVIC connector. The design of the connector prevents potential contact with high voltage due to the time required to disassemble the connector.
- Page 35 Drive Motor Battery Fuse Cover The drive motor battery fuse cover is accessible from the front of the battery and contains high voltage. Both the main and charger HVIC loops connect through the fuse cover. If the fuse cover is removed with high voltage turned on, the contactors open to reduce the risk of electrical shock.
- Page 36 Manual Service Disconnect Access to the MSD is from the inside of the vehicle, underneath the center console box. The MSD interrupts the high voltage circuit within the drive motor battery. As the MSD is removed, the design causes both the main and charger HVIC circuits to open prior to high voltage circuit opening.
- Page 37 Drive Motor / Generator Power Inverter Module Cover Remove the drive motor / generator power inverter module cover to access the high voltage connectors. The circuit opens when the cover is removed. The system is designed to shut down high voltage by opening the contactors in the amount of time it takes to access the high voltage circuits.
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Page 38: High Voltage Labels
High Voltage Labels The Chevrolet Volt features a series of high voltage labels that enable quick identification of potential electrical hazards. The labels are attached on each high voltage component. The labels are color coded to indicate the potential high voltage... - Page 39 High Voltage Labels The emergency / service personnel warning label is affixed at the front of the engine compartment and provides specific procedures for emergency personnel. The high voltage danger labels are red and indicate that high voltage is present at all times.
- Page 40 High Voltage Labels & First Responder Tags The First Responder cable cut tag is wrapped around the low voltage positive battery cable and is located in the rear compartment behind the fuse panel door. To help ensure that low voltage is not holding the high voltage contactors closed, first responders will cut the cable before an...
- Page 41 Inspection The hybrid powertrain control module 2 will open the high voltage contactor relays and disable the vehicle whenever a SIR deployment occurs. A complete inspection of the high voltage system and components must be performed in accordance with service information if the vehicle has been involved in a collision.
- Page 42 High Voltage Disabling Full disabling and removal procedures are located in the GM service manual for the vehicle. Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed. The High Voltage Disabling procedure will perform the following tasks: •...
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Page 43: Hv Battery Removal
HV Battery Removal The used battery must be removed and returned with a battery assembly lifting fixture (GM Special Tool EL-49976.) This lifting fixture will be attached to the used battery and placed in the shipping cocoon. Each new service battery will come with a battery assembly lifting fixture for use during installation. - Page 44 HV Battery Shipment Lithium-ion batteries are considered hazardous materials and require special shipping regulations. Lithium-ion batteries are classified as Class 9 hazardous material. Identifications (referred to as UN numbers) exist for the various battery packs based on chemistry and configuration. Refer to the return shipping instructions included with the replacement battery for specific identification needed for transportation.
- Page 45 Handling Fire If battery cells reach high enough temperature, they vent and release electrolyte. Battery electrolyte is flammable. Use copious amounts of water to cool the battery and extinguish the fire. ABC dry chemical extinguisher will not extinguish a battery fire. Water The high voltage battery is sealed and isolated from the vehicle chassis.
- Page 46 Conclusion General Motors is committed to making your job as safe as possible. We are confident the information contained in this guide will prove useful. Always refer to General Motors Service information for additional details and procedures. 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.