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Chart based on 110 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2018 Chevrolet Volt 4dr Hatch
149-horsepower Plug-in Hybrid CVT FWD
141000 mi
US $700
Replaced EGR valve and EGR valve cooler.
144000 mi
Replace catalytic converter and oxygen sensor
High voltage charging failed after routine LOF required loaner and overnight repair. The dealer didn't know what they did, or would not tell me, but they indicated quite clearly that they messed it up.
53940 mi
MIL came on with no symptoms. Code P1e00 manufacturer control fault. Took to dealer, part ordered. Still waiting in June, but car is fully functional.
3720 mi
Active shutter grill stopped working. Check engine light on. Dealer replaced Active shutter grill under warranty.
Check engine light went on. A TSB was issued for emission repair. The dealership told me that Chevrolet was still trying to find a solution to the problem. The dealership cleared the fault code and the check engine light hasn't appeared since.
36000 mi
Emissions tube was rubbing and wore through the line. Required pulling the engine to gain access to and replace the line.
14000 mi
When operating on gas engine (either with some electric range left or with none left), from a near or complete stop, accelerating will create a bang sound from the exhaust. From online searches, this appears to be an afterfire sound (similar to misfire or backfire, but happens in the exhaust).
My dealer did a wonderful job troubleshooting and ruling out other causes of the bang but ultimately consulted GM engineer who claimed this was normal despite nearly all other 2016/2017 Volt and 2011-2015 Volt owners never experiencing this issue.
Please see following video recordings of my Volt making the sound (I used fake name for anonymity):
https://vimeo.com/228493984
https://vimeo.com/228494160
Another 2016 Volt owner in California has the same issue:
https://vimeo.com/177954038
The issue gets worse as the exhaust gets warmer so the hotter it is, the more bang sounds you will get.
4000 mi
Failure at 4,000 miles - high voltage fuse blew, car wouldn't work in EV mode at all even though it was brand new. Sat in dealership lot for 2+ weeks waiting on parts.
9000 mi
reduced propulsion recall
25200 mi
Leaking oil from the oil pan
2000 mi
Remove and re-apply oil pan sealant.
17000 mi
The check engine light erroneously lit up due to an issue with the software on the power inverter. The dealer was able to identify the problem (service bulletin) and reprogram the power inverter. As far as I know there was no mechanical issue.
17360 mi
Battery energy module update done and check for loud buzzing (intermittent) when charging - nothing found
54560 mi
EV battery control module failed causing the vehicle to be rendered inoperable. Vehicle was towed to dealer and the module was replaced under the drivetrain warranty.
37000 mi
EGR valve went bad.
45000 mi
Hybrid ICE fails to run in HOLD mode. Bucks and runs severely during operation. Taken to dealer that states several error codes indicate communications issues and misfire issues between ICE and computer/modules. Left for dealer.
25856 mi
Routine 3k maintenance and tires rotated.
33000 mi
O2 sensor shorted, which also blew the associated fuse. Fixed under Voltec warranty.
13000 mi
Check Engine light on, but no underlying cause. Dealer is checking with engineers in Detroit.
Check engine light, EGR needed replacement, maybe related to transmission change, damaged original valve during disassembly/reassembly
6200 mi
Car died on Florida turnpike, no power and "shift to park" message. GM replaced what they call an "F module" which I later learned was power inverter module that sits on the tranny.
44640 mi
EGR valve failed. The failure invoked a short in the coil which also took out fuse F3 ( non walk home fuse) which takes out cooling control, even on electric,
This failure is quite common on G2 volts. Delver told me that he know an owner where this has happened 4 times
Repaired free under emissions warranty
55800 mi
On way home from Florida, threw a P2097 emission systems code. Post O2 sensor.
Engine performed normally but engine temp went up from 195F to about 230.
After 4 or 5 stops ( gas, hotel stay) I noticed engine temp began swinging from 180 to 230F, all during constant speed driving. Then check engine light went out and engine temp went back to iits normal 195-205 range.
Shop found another software update from about 2018 addressing this false flag. I had this issue before in 2016 and an update was supposed to s correct this but it seems further updates were necessary
Corrected under warranty
8000 mi
Recall for hesitation
55000 mi
Gas engine failed to start after the electric motor battery was depleted. Car was towed to dealer. Dealer unable to find a problem. Oil pan leak
19000 mi
Factory coolant hose configuration was causing it to rub. Hose eventually ruptured and leaked coolant. Dealer replaced hose.
44000 mi
Catalytic converter- covered under warranty
3899 mi
Engine idled extremely roughly in cold; replaced fouled spark plugs.
27000 mi
Then two weeks later the gas engine sputtered while going uphill. The local dealer looked at the car, and said the FUEL INJECTOR SEALS had not been replaced by the other dealer when installing the new engine. The seals were on back order for two weeks, so I had a loaner car while the replaced the injector seals in the new engine. The gas engine seized during highway driving, as a cooling hose came off the engine block. The engine overheated and siezed. The dealer replaced the engine.
14000 mi
Software update for Engine Idle and Cameras
Normal Oil, Lube Tire Rotation
1700 mi
The electric drive module was faulty, causing a CEL and needed to be replaced
On-board high voltage charging modules damaged by water intrusion. All components replaced under warranty.
67400 mi
US $17
High Voltage service needed for Low coolant for the Battery, did not need to change the sensor though I thought I would need to. Have not checked the battery drain yet for leaks at this time. It was not super low but just enough to trip the sensor. I made appointments at 2 different chevy dealer and neither had a tech that new Volts to service it.
41000 mi
US $118
HPCM2 Computer reprogrammed and battery capacity re-learn procedure done. EV range returned to normal. The repair was covered by the 8 yr./100,000 mile Voltec warranty. I probably should have contested the $118 diag charge, but I was just happy to get my car back.
Car would not charge. Diagnosis revealed a hairline crack in vehicle's charge port receptacle which caused short in system. Charge port receptacle replaced under warranty
27590 mi
Charge port was shorted and had to be replaced
56000 mi
Section 3 of the Voltec system showed abnormally low voltage, so the battery section was replaced under Voltec warranty. This caused sudden stalling of the vehicle on the highway as it transitioned from EV mode to engine.
38300 mi
Problem with battery cooling system, replaced "battery coolers".
78000 mi
replaced hybrid control unit
82000 mi
replaced charge port, covered under Voltec warranty
8000 mi
Charging system stopped working.
22000 mi
Replaced auxiliary coolant pump for cabin heat. Part on NBO, took a week to get part.
3720 mi
Volt refused 240v charging but accepted 110v charging. Dealer changed a computer. Won't be clear if fix was successful until we have another downpour.
9920 mi
Car would not accept a charge from either 110 or 220 charging stations. The charging socket in the front left fender was replaced with one less likely to soft ground faults.
44150 mi
After a heavy rain my Volt wouldn't charge anymore when plugged in. I took it to the dealership who diagnosed a charge receptacle failure. They replaced the charge receptacle at no cost to me because it was still under warranty.
10500 mi
Auxilary coolant pump failed and needed to be replaced. Dealer took some time to source a new part to be replaced under warranty.
34000 mi
Intermittent propulsion battery charging. Faulty battery charger cable ordered a new one.
55000 mi
Cabin heating was virtually non-existent in all-electric mode. Dealer found a software update was due that would address this issue, so they applied the update. The update did seem to fix the issue, but other parts were also faulty, so in the end, this update did not fix my no-heat issue in all-electric mode. The heat stopped working in all-electric mode. Technician diagnosed faulty Heater Coolant Control Module and/or faulty Auxillary Coolant Pump, and replaced both under GM High Voltage Warranty. Ops check good.
120897 mi
US $250
2 computers, BECM & HPCM2 each required an updated calibration to stop the car from throwing CEL related to loss of high voltage isolation in coolant system.
38000 mi
US $600
Coolant circulation pump went bad and electric heat was not available. Pump was replaced
72000 mi
US $700
Heat in ev mode was not working. Needed a new circulation pump.
59000 mi
Battery cooling system valve
80600 mi
Rock damage to radiator
11700 mi
Charging port failure
8000 mi
"Service High Voltage Charging System."
Was unable to charge the EV Battery
21500 mi
Heater didn't work when driving electric. An electric water circulator pump was replaced under warranty.
32000 mi
The Volt would not start up or drive. The dash would illuminate and display several error messages including "service power steering soon" and "service theft deterrent system." Repairs included: 1st dealer replacing Power Inverter Module (PIM) ) [backordered through GM for a month and a half] and HPCM2. Second dealer replaced another unknown part and vehicle is now fixed.
27780 mi
Drive Motor Battery Coolant level Sensor replacement
New sensor installed free of charge
24500 mi
The car would not charge when plugged in. The problem may have been caused by heavy rain. The dealer replaced the charge port with an updated part to prevent rain damage. Problem fixed.
Check engine light on - charging error codes were noted and the system was reset.
hole in radiator for battery coolent loop. still drivable on gas engine. covered under a tsb from 2014 where they increase the size of the radiator protection screen. also added an aftermarket screen on the grill.
19500 mi
Electric charging non-functional.
2700 mi
The check engine light came on.
99000 mi
US $60
Electrical coolant pump failed
42300 mi
The service engine light came on every time it rained for a long time now. Moisture getting in near charge port. TSB for it. They put some lubricant in there. Did not fix issue as light came on a few days later when it rained again.
56300 mi
Vehicle would not charge
Check engine light on
Computer update
12000 mi
Broken tab on charging unit
13500 mi
Bearing noise from electric motor - driven straight to dealer (~1 mile). Bearing found to be failed Bearing replaced. Bulletin PIP5081D
30000 mi
Loose transmission mount caused a clunk under braking. No parts replaced, just tightened.
40000 mi
Car charger no longer worked.
5000 mi
Delayed charging feature could switch the car into charging mode while driving, thus disabling the electric propulsion system. I experienced this problem prior to the recall/"customer satisfaction campaign" was released.
63000 mi
US $1200
Battery cooling fluid leaking. Supposedly due to rock damaging the radiator. Replaced radiator.
36980 mi
Replaced charge port door
6820 mi
Solenoid for pin used in charge port door.
11780 mi
Car was getting water in behind charge port connections and caused a charging issue.
2000 mi
Had a loud whining noise when slowing down
Service advisor said needed campaign PIP-5081 - repair complete and noise is no longer there
21000 mi
Charge Port door would not open without force, replaced with updated door under warranty
5700 mi
Battery cooling fluid was low.
31000 mi
Car could not be charged through plug in connector.
13000 mi
CEL, returned soon afterwards charger door broke, new door still not operating properly
15300 mi
Core replaced
77500 mi
US $80
Check engine light brought on by faulty fast charger. Dealer found an error in the system & resolved it.
48000 mi
Input shaft bearing cage between drive unit and motor failed. Car drove fine and no permanent damage but made loud noise during deceleration. Fixed under warranty. Warranty is up to 150,000 miles.
16000 mi
Car stopped charging. Repair of the electromotive charging module; replace battery coolant. The dealer quickly made the warranty repair and then saw a TSB about a change in the connector, recommended for any car that had a charging problem. Ordered part.
10500 mi
EV charging system TSB
31000 mi
US $400
Recall work done, emissions related and trunk struts.
53400 mi
Idle shut off updated to ten minutes.
35000 mi
US $1200
Rear transmission mount broken, causing tension on transmission cooler lines.
mount and cooler lines replaced.
50840 mi
Volt modules HPCM2 and ECM would sometimes cause the car to drive on gas despite a full battery. Reprogramming and observation to make sure the problem was solved.
108000 mi
US $1098
Motor mount right side
5500 mi
The plug in battery was not recharged overnight and the board displayed the check engine light.
8000 mi
Battery would not do a delayed charge
85000 mi
US $200
check engine light came on, replaced gas cap, came on again, still on, no idea why
86000 mi
US $100
check engine light came on, had to replace gas cap
72000 mi
US $2500
Vehicle was unable to charge the propulsion battery when plugged in. Battery charger control module diagnosed as failed. $1500 part, was not available due to chip shortage, backordered with no delivery date. $1000 estimated labor.
80000 mi
Replace part on Electric Drive System - Warrantee repair. Earlier had to reprogram control software.
400 mi
2013 Volt less than 24 hours old had engine overheat. Taken to dealer and radiator was defective.
17000 mi
Charging port was replaced
72000 mi
US $19
Lithium ION battery pack was replaced due to "Propulsion Power Reduced" error message.
8000 mi
Charging system sensor
18300 mi
Check engine light with "Service high voltage charging system" message. Determined battery coolant was low. Purged air and added coolant
23500 mi
Battery coolant radiator is low and unprotected. I got a nail kick-up by a truck in front of me in it, coolant leaked and the car would not charge. Repaired free per (TSB #13-06-02-001 NHTSA ID #1005204)
23000 mi
Charge receptacle shorted out and was replaced under Voltec system warranty.
21000 mi
Vehicle would not charge. Lots of trial-and-error. It took 19 total days to find the root cause and repair it at the dealership. Eventually, the charging control module ("HPCM-2") was replaced, which solved the problem.
Cooling fluid for high voltage battery system was low, causing the car to not charge at all.
http://www.greencarreports.com/news/1092845_gm-offers-free-fix-for-2012-13-chevrolet-volt-battery-coolant-issue
Check engine light came on after plugging into public charging station. Dealer could not duplicate the problem. Check engine light was reset and problem has not happened again.
42200 mi
Defective bearing connecting electric and gas motors
2000 mi
"Customer Satisfaction Enhancement" performed on the car--related to the battery cooling system. No discernible problems before the action, no discernible differences since.
6000 mi
Check engine light illuminated. Car driveable. Dealer had car overnight. Found software issue. Possibly realted to very hot weather. Problem resolved. Dealer reported it to GM.
17000 mi
Trouble message re: charging system. Car was driveable but would not charge. Dealer found software issue and repaired under warranty.
51150 mi
C $100
Second replacement of EVSE that stopped working. Car charging fine, but EVSE not functioning. Cost was for deductible to diagnose problem. It didn't light up at all - pretty obvious problem, but cost me $100 nonetheless.
16500 mi
Thermostat stuck open. It was replaced
54000 mi
Check engine light, slight drive ability issue
43762 mi
US $187
Repaired broken wiring at battery coolant jug level sensor. Had intermittent warning that high voltage charging system needed maintenance. Until this repair, all the dealer did was reset the codes, but the problem recurred every few months. Hopefully, this will be a permanent fix.
2700 mi
Intermitent check engine light that has not returned. dealer believes to be a "growing pain" while the car adjusts to the local heat. The code was an engine intake air to hot code.
1000 mi
Replaced cracked bus connector. Cracked connector allowed intermittent pin contact causing engine computer to believe there was a problem with engine. Computer shut down engine to protect it.
3800 mi
CEL came on during road trip. Went to dealer next day but light was not lit. Tech said that the DTCs were random. Codes were cleared and he will look for them next time car returns for work. Codes were P0700, P0712, P1AF0, P1AF2 and P1E22.
112000 mi
US $400
Transaxle motor mount
18000 mi
Got this notice, "Service High Voltage Charging System" After this the car wouldn't charge. This was caused by low traction battery coolant which the dealer topped off.
43000 mi
High charging system failed. Replacement of high voltage charging module.
59920 mi
Charge cord stopped working and needed replacement
7300 mi
Multiple systemic failures starting with the AC and cascaded to other critical electrical systems including those that manage the power train.
8000 mi
Volt has been in the shop for over 60 days now for an issue with computer sensors and the battery electric motor system. So far, no resolution.
9200 mi
The dealership was unable to determine the true root cause. They ran sensor wires through different pathways in the engine compartment and the problem ceased to re-appear. Actual time to repair was 108 days.
19000 mi
Same issue as last year about this time. Catastrophic failure of the high voltage charge system. High capacity charge system reported a fault. Dealer flashed firmware of computer to latest version which they say will resolve the issues. So far, no further incident.
20460 mi
Check engine light blinking, misfire, cylinder head had to be replaced. Details : http://gm-volt.com/forum/showthread.php?116146-Cylinder-head-had-to-be-replaced
34720 mi
Coolant smells when cabin heating is "On" and gas engine begin to run. When engine coolant reach about 30°C, coolant odour smells inside the for about 1 minute. Dealer change a part but the problem is there anyway after the repair.
47000 mi
Battery coolant low causing a check engine light. Vehicle brought to dealer and sensitivity to low battery coolant level brought down with an ECM update. Refilled coolant and vehicle could then drive again on electric propulsion.
49000 mi
Charge port had water intrusion causing a ground issue for the vehicle. When plugged in, the EVSE would start and stop charging multiple times per minute until unplugged. A car wash caused the issue where water had caused water intrusion. The dealer replaced the entire charge port under the Voltec warranty.
59000 mi
Front radiator, which is for cooling the inverter and drive motor, had a stone hit one of the tubes of the radiator and it was leaking coolant. Radiator replaced under 8 year/100,000 mile Voltec warranty. There is a TSB issued for the problem and the dealer took care of it with no further questions.
61000 mi
2011 and 2012 Volts can have reduced propulsion power after shutting down and restarting in charge-sustaining (gas) mode. A software update was applied which changed the minimum state of charge for the vehicle so it does not go into reduced propulsion power mode. It unfortunately also reduces the total available electric range of the vehicle.
27000 mi
Replaced exhaust camshaft actuator.
32000 mi
Failed to charge high voltage battery. Service High Voltage Charging System warning. Service department repaied faulty splice (from factory) in wire harness for high voltage battery coolant level sensor and reprogrammed a module.
70700 mi
US $120
Check engine light on. Had to do with plug in.
108000 mi
US $950
Hybrid battery would not charge. DTC showed bad sensor, pump, and reservoir for battery coolant.
116000 mi
Hybrid battery would not charge again. DTC showed bad sensor, pump, and reservoir for battery coolant.
36580 mi
misfire on 3 cyl. They changed the engine head for a new one.
55620 mi
Propulsion battery heater broken. Had to replace module.
17000 mi
EVSE Charger malfunctioned and wouldn't charge the car. Chevy replaced under Voltec warranty.
26000 mi
US $250
O2 Sensor for gas engine failed...triggering check engine light.
13075 mi
Strong emissions smell in the car..
Also strong oil burning smell in car.
Turned out to be a rotten exhaust replaced under warranty. Head gasket found to also be leaking and replaced under warranty. Replaced the full exhaust, muffler, pipes, cat, manifold, and gaskets, and still had smell..
The car stopped accepting a charge. A component of the charging system was replaced, and the power inverter module was reprogramemd.
63200 mi
US $400
Battery cooling system radiator replaced. Damaged by road debris due to placement/lack of protection. Additional protective screen installed per bulletin. Dealer software required to fill/purge battery cooling system - DIY not possible.
63000 mi
Received a check engine light, a message to service the HV charging system, and car would not charge. Dealer found an intermittent connection to the battery coolant level sensor after three trips.
88000 mi
US $165
Hivoltage charging system had error message showing service immediately. Software updated at my expense. Disappointed as I felt this should have been covered by the existing drivetrain warranty.
98000 mi
US $320
Second high voltage charging system problem indicator. Cause was another software update needed by the high voltage system. Dealer claimed it would be covered if there was a hardware issue, but since there was no hardware issue, owner is responsible for payment. How can Chevy not claim this should be covered by Chevy drivetrain warranty.
99000 mi
Hi voltage charging system error message and unable to charge car. (3rd time). Finally the third dealer found it was not a software update as the prior 2 dealers but was instead due to a failed drive motor battery coolant level sensor. Replacement of the sensor (at no cost under warranty). Hopefully fixed issue but even more disappointed with the other 2 dealer visits that missed the problem and charged me for software updates.
101000 mi
US $215
Charger Assembly defective, unable to charge. Replaced high voltage assembly.
8000 mi
A light was on in the dashboard. They read the computer and said it was a "failed evaporative emissions pump". Item needed to be special ordered and is back ordered.
9000 mi
Replaced the Evaporative Emissions Pump
8700 mi
Car would not charge with either 240V or 110V chargers. Problem was with a cooling system for the battery.
16200 mi
US $95
Volt stopped being able to charge. A warranty software update was required to fix the problem. While I was there, I also rotated the tires, replaced the cabin air filter, and did an oil change.
Coolant sensor. Covered by 8 year Voltec warranty.
96000 mi
US $54
Received a "service high voltage charging system" message. Took vehicle in and the coolant for the battery pack was low. This was covered by the battery warranty.
100000 mi
The charging cord stopped working and was replaced under warranty.
54000 mi
Coolant leak on drive motor - replaced radiator under warranty
77000 mi
US $500
Engine light on. Car performed fine. Could not trace cause of it for extended period. Eventually found wiring fault and corrected.
Main EV Battery Failure. Car dead. Left it at the dealer. Bought another EV.
45000 mi
Problem with wiring harness running to the low coolant level sensor.
65300 mi
Coolant sensor
40000 mi
Charger door wouldn't open. Dealer replaced door under warranty.
25400 mi
US $500
bad battery temperature sensor
26000 mi
EVSE (not the car) need replaced.
29700 mi
msg - service high voltage charging system
Something about battery coolant level. replaced connector per PI0961C. - There is recall doc on this...
58000 mi
Chevy Volt's gas engine should turn on when main battery is drained. Battery failed to report it was drained so gas engine would not turn on. Car basically shuts down.
Dealer replaced 4 battery modules and battery's 'brain' (forget the part name). Cost of repair totals $2700+ but was covered under electrical system warranty...
See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how
frequently Chevrolet Volt problems occur, check out our car reliability stats.
