Chevrolet Bolt EV 2017-2020 Service Workshop Manual

Chevrolet Bolt Workshop, Owners, Service and Repair Manuals. Error Codes and Electrical Wiring Diagrams

20MY Owner’s Manual Download
General Information Download
Automatic Stop/Start Disable Download
Reminder Indicator Reset Procedure Download
Canadian-To-U.S. Model Reference Tables Download
Cellular, Entertainment, and Navigation Download
Common Specs and Procedures Download

Emission Control Abbreviations (Gasoline & Diesel) Download
Traction Control, 4WD, & AWD Download
Uniform Inspection and Communication Standards Download
Accessories and Equipment Download
Bolted Exterior Body Panels and Closures Download
Bumpers and Fascias Download
Cruise Control Download
Data Communications Download
Displays and Gauges Download
Exterior Trim Download

Fixed and Moveable Windows Download
Floor Coverings and Headlinings Download
Frame and Underbody Download
Horns and Pedestrian Alerts Download
Immobilizer Download
Instrument Panel and Console Trim Download
Interior Trim and Paneling Download
Lighting Download
Luggage Rack and Roof Trim Download

Mirrors Download
Object Detection and Pedestrian Protection Download
Power Outlets Download
Remote Functions Download
Seat Hardware, Trim, and Upholstery Download
Seat Heating and Cooling Download
Secondary and Configurable Customer Controls Download
Theft Deterrent Download
Vehicle Access Download
Wipers and Washers Download
Wiring Systems and Power Management Download

Maintenance and Lubrication Download
Firing Order & Cylinder Identification Download
Automatic Transmission – 1ET25 (MMF) Download
Electronic Transmission Range Select Download
Suspension General Diagnosis Download
Front Suspension Download
Rear Suspension Download
Tire Pressure Monitoring Download
Tires and Wheels Download
Wheel Alignment Download
Wheel Alignment Specifications Download
Power Steering Download
Steering Wheel and Column Download
Antilock Brake System Download
Disc Brakes Download

Hydraulic Brakes Download
Park Brake Download
Wheel Drive Shafts Download
HVAC – Automatic Download
Heating, Ventilation, and Air Conditioning Download
Seat Belts Download
Supplemental Restraints Download
Paint and Coatings Download
12V Starting and Charging Download
Wiring Systems And Power Management Download
Data Communications (EWD) Download
Door Component Views Download
Electrical Center Identification Views Download

Front of Vehicle Engine Compartment Component Views Download
Instrument Panel Center Console Component Views Download
Luggage Compartment Rear of Vehicle Component Views Download
Passenger Compartment Roof Component Views Download
Wheels Vehicle Underbody Component Views Download
Splice Pack Connector End Views Download
Inline Harness Connector End Views Download

Powertrain Component Views Download
Master Electrical Component List Download
Ground Views Download
DTC Index Download
Hybrid/EV Controls Download
Hybrid/EV Energy Storage Download
Hybrid/EV System Heating and Cooling Download
Plug-In Charging Download
Special Tools and Equipment Download
Schematic Wiring Diagrams Download

Production of two General Motors long-range electric vehicles, the Chevrolet Bolt EV and Bolt EUV, has been put on hold, ostensibly due to an ongoing shortage of semiconductor chips.
GM‘s extended recall now covers all 142,000 of the two Bolt models sold since 2017, including 2022 models on show floors because electric vehicles can catch fire. Now the company is waiting for new battery packs, which eliminated a number of manufacturing defects.

Chevy is the latest manufacturer to recall its battery-powered vehicles due to fire risk, but it’s not alone. Hyundai extended a similar recall earlier this year to around 90,000 of its Kona EVs. Ford has recalled more than 20,000 plug-in hybrids in Europe because they could also overheat and catch fire. Tesla products have also been linked to several fires.

Such reviews proved to be costly. Two service promotions specific to the Chevrolet Bolt alone will cost the manufacturer about $1.8 billion. The Kona recall cost Hyundai about $900 million. But the consequences of such reviews and news coverage could have much more serious consequences in the long run, industry insiders fear.

Battery fires are not unique to the automotive industry. In 2019, the Federal Aviation Administration and the U.S. Department of Transportation jointly banned lithium-ion batteries as cargo on passenger aircraft and restricted their transportation on cargo aircraft. Several incidents, including the crash of a UPS 747 in 2013, have been linked to battery fires. In addition, concerns have been heightened by defects that have caused a number of Samsung smartphones to catch fire.

Battery manufacturers and the automakers they serve claim the technology has been greatly improved, and Tesla CEO Elon Musk has repeatedly insisted that the risk of an EV battery fire has been greatly exaggerated.

Two types of battery fires

When battery fires do occur, they fall into two categories. Some result from an accident that damages and shorts out the unit, causing individual elements to catch fire. This happened to Tesla products early on, which led the automaker to add extra protection around the blocks on cars like the Models S and X.

However, the attention of the media was attracted by the fires that occurred during the parking of cars – in some cases in the garage. In some, but not all, of these Chevy Bolt situations, the cars were connected to chargers. One such fire severely damaged a home in Port St. Lucie, Florida last October.

GM traced the issue to a manufacturing defect at the battery supplier’s LG Chem subsidiary. The automaker is pushing for the South Korean automaker to cover most of the cost of the current recall. Manufacturing issues with LG Chem’s batteries also caused the Kona EV to be recalled.

Although the number of EV fires is relatively small, experts note that if a lithium-ion unit catches fire, it can be extremely difficult for special services to deal with a fire.

Solution of problems

A number of automotive industry executives contacted by Forbes Wheels admitted to being concerned about battery fires and the publicity they generate. By all accounts, as production grows and lithium-ion technology is explored, problems like those of the Chevrolet Bolt and Hyundai Kona are being addressed. GM claims they have eliminated these issues when developing new Ultium batteries that will power future EVs such as the GMC Hummer and Cadillac Lyriq.