PIP4859C Service Bulletin/Repair Instructions

File in Section:
Service Bulletin
Bulletin No.:

Date:
PIP4859C

September, 2013
PRELIMINARY INFORMATION

Subject:
(EREV Volt) Vacuum Coolant Fill Information
Models:
2011-2014 Chevrolet Volt

2012-2014 Opel Ampera

with 1.4L engine (RPO LUU)

This PI was superseded to update model list. Please discard PIP4859B.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Condition/Concern

When preforming ANY cooling system repairs or component replacement that requires opening any one of the

Chevrolet Volt's cooling systems it will be necessary to use a vacuum fill procedure to ensure the cooling system is

properly filled.
Recommendation/Instructions

Make sure to follow published SI procedures when refilling any one or all of the vehicles cooling systems. All cooling

systems require a vacuum fill procedure using GE-47716 Vac-N-Fill Coolant Refill Tool or equivalent.

Failure to properly fill the cooling systems can cause overheating, DTCs, loss of charging, noises and or

misdiagnosis.

After filling the battery cooling system, it will be necessary to follow the procedure below to purge air from the RESS

system:

Use Vac-N-Fill procedure to pre-fill to pack with coolant and only after initial coolant fill initiate coolant bleed

procedure.

Important: Draining of the cooling system or replacement of any drive motor battery cooling system parts requires

the actuation of the Hybrid/EV Battery Pack Coolant Pump Bleed Procedure in the GDS2 tool. Place vehicle in

Service Mode. With the GDS scan tool, initiate the hybrid/EV battery pack coolant pump bleed procedure while

maintaining 381 mm (15 in Hg) vacuum throughout the process. This procedure will take about one hour to complete.

During this coolant procedure you will need to maintain sufficient coolant in reservoir as air is purged.

After performing the GDS2 coolant bleed procedure drive vehicle for approximately 5 miles in a slalom type of

situation (side to side motion) to purge any remaining air from battery pack cooling plates.

Check for DTCs, clear if necessary and top off coolant system.
ADDITIONAL SI KEYWORDS:

board charge CHCM fluid heater leak module OBCM on PIM pop rattle valve

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is

resolved without completing every step, the remaining steps do not need to be performed.

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