The 2016 Spark EV is a compliance-car electric with a robust powertrain but typical GM build quality issues. Most problems stem from battery degradation, cooling system quirks, and the usual cheapness in trim and HVAC components rather than catastrophic drivetrain failures.
High-Voltage Battery Capacity Loss
Common · medium severityTypical onset: 70,000-100,000 mi
Symptoms: Range drops below 60 miles on full charge, Battery capacity reported under 50% on diagnostic scan, Rapid State of Charge swings, Increased charging times
Fix: Battery pack replacement is the only real fix. GM discontinued factory packs, so you're hunting used or aftermarket refurbishment. Labor is 6-8 hours due to underbody access and high-voltage disconnect procedures. Many owners just live with degraded range.
Estimated cost: $4,500-8,000
Onboard Charger Failure
Occasional · high severityTypical onset: 60,000-90,000 mi
Symptoms: No charging from Level 1 or Level 2 EVSE, Charging fault codes (P1E00, P1E0A), Charger port LED stays dark or flashes red, DC fast charging still works but AC charging dead
Fix: Onboard charger module replacement. Unit is integrated into the front of the battery pack assembly. Requires high-voltage safety lockout, coolant drain, and module swap. 4-5 hours labor. Used parts are the only option now.
Estimated cost: $1,800-3,200
Electric Drive Motor Bearing Noise
Occasional · medium severityTypical onset: 80,000-120,000 mi
Symptoms: Whining or grinding noise proportional to speed, Vibration through floorpan during acceleration, Noise changes pitch with regenerative braking, No loss of power initially but noise worsens over time
Fix: Drive motor R&R required. Front subframe drop, disconnect high-voltage cables, remove transaxle assembly, and replace motor unit. This is a 10-12 hour job with alignment afterward. Used motors from salvage are common, rebuilds are rare.
Estimated cost: $2,500-4,500
Thermal Management System Coolant Leaks
Common · medium severityTypical onset: 50,000-80,000 mi
Symptoms: Orange coolant puddles under vehicle, Low coolant warning on dash, Reduced power mode due to overtemp protection, Visible coolant staining around battery pack perimeter or inverter connections
Fix: Battery cooling system uses quick-connect fittings that crack and leak. Leak location determines labor: inverter hoses are 2-3 hours, battery pack perimeter hoses require partial pack removal (6-8 hours). Parts are cheap, labor kills you.
Estimated cost: $400-2,000
12V Battery Premature Failure
Common · medium severitySymptoms: No start even with full HV battery charge, Accessories dead, no dash lights, Click from contactor but no ready mode, Battery voltage under 11.5V after sitting overnight
Fix: The 12V system works harder in EVs due to constant computer draw. OEM battery rarely makes it past 3-4 years regardless of mileage. Simple swap, 0.5 hours, but requires HV disconnect procedure for safety. Use a quality AGM replacement.
Estimated cost: $200-350
Shifter Position Sensor / Inhibitor Switch Fault
Occasional · medium severityTypical onset: 60,000-100,000 mi
Symptoms: Vehicle won't shift out of Park, Gear position display incorrect or blank, Fault codes P0706, P0707, Intermittent no-start when shifter is in Park
Fix: Shift-by-wire system uses a position sensor on the shifter assembly that fails. Replace shifter module and recalibrate via Tech 2 or MDI. Labor is 2-3 hours including programming. GM part only.
Estimated cost: $600-1,000
HVAC Blower Motor and Resistor Failure
Common · low severityTypical onset: 40,000-70,000 mi
Symptoms: Blower only works on high speed, No air flow at any setting, Squealing or grinding from dash, Intermittent operation, works after hitting bumps
Fix: Typical GM cheap blower resistor and motor assembly. Access is good — drop glove box, replace resistor (0.5 hours) or motor (1.5 hours). Parts are under $150. Not unique to EV but extremely common on this platform.
Estimated cost: $150-400
Buy one under $8k with verified good battery health and you'll have cheap city transport; anything needing a battery or motor replacement exceeds the car's value.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.