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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Symptoms: 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 severity
Typical 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 severity
Typical 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
Owner tips
Check battery State of Health (SOH) with a Torque Pro adapter before buying — anything under 60% means replacement is imminent
Inspect coolant hoses around battery pack and inverter for orange staining during every service — catch leaks early
Replace the 12V battery every 3 years preemptively to avoid being stranded
DC fast charging accelerates battery degradation — if the previous owner hammered it with DCFC, expect range loss
Test both Level 1/2 AC charging and DC fast charging before purchase — onboard charger failures are expensive and parts are scarce
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.
Fitment notes: 12V auxiliary battery for accessories; high-voltage traction battery separate
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Every control module on the 2014-2016 Chevrolet Spark EV — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
Battery Energy Control Module (BECM)2.5 hr R&Rdealer / factory tool +1.0 hr▸ programming details
📍 Integrated with high-voltage battery pack assembly under rear cargo floor
📍 Under hood, mounted to hydraulic control unit on left front shock tower
🔧 GM SPS2 via MDI
⚠️ Integrates ABS, traction control, stability control, and regenerative braking coordination; bleeding and automated function tests required after replacement
Park Assist Control Module (PACM)1.0 hr R&Raftermarket tool +0.2 hr▸ programming details
📍 Behind rear bumper cover, center
🔧 GM MDI or Autel MaxiSys
⚠️ Optional equipment. Ultrasonic parking sensors. Basic relearn procedure available with aftermarket tools.
Radio / Infotainment Control Module (RDO)1.0 hr R&Raftermarket tool +0.3 hr▸ programming details
📍 Behind center stack, integrated with 7-inch touchscreen display
🔧 Tech 2 or Autel
⚠️ MyLink system; VIN configuration and theft deterrent relearn recommended but not always mandatory for basic function
📍 Behind instrument panel, center of driver's side dash
🔧 GM SPS2 via MDI
⚠️ Odometer programming and VIN configuration required; displays EV-specific range and charge information
Remote Control Door Lock Receiver / Theft Deterrent Module (RCDLR)0.7 hr R&Rdealer / factory tool +0.4 hr▸ programming details
📍 Behind right side of instrument panel, near glove box
🔧 GM SPS2 via MDI
⚠️ Receives key fob signals; key fob programming and theft deterrent relearn required after replacement
Rear Vision Camera Module (RVCM)0.5 hr R&Rrelearn only +0.2 hr▸ programming details
📍 Integrated with rear liftgate handle assembly
🔧 Tech 2 or Autel
⚠️ Standard equipment; camera calibration/alignment typically automatic after installation
Transmission Control Module (TCM)no coding
📍 Not present - single-speed reduction gear with no electronic shift control
⚠️ Spark EV uses fixed-ratio reduction gearbox; no traditional transmission control module exists
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
General Motors LLC (GM) is recalling certain model year 2014-2016 Buick Lacrosse and Chevrolet Spark EV, Caprice PPV and SS vehicles, 2014-2017 Buick Encore and Chevrolet Corvette, Silverado 1500 and GMC Sierra 1500 vehicles, 2015-2016 Cadillac Escalade and Escalade ESV, Chevrolet Tahoe, Trax, Suburban and Silverado 2500 and 3500 and GMC Yukon and Yukon XL vehicles, and 2015-2017 GMC Sierra HD 2500 and 3500 vehicles. While being previously remedied for recall 16V-651, the affected vehicles may not have received the complete software update necessary to remedy the recall condition. Without the update, certain driving conditions may cause the air bag sensing and diagnostic module (SDM) software to activate a diagnostic test. During this test, deployment of the frontal air bags and the seat belt pretensioners would not occur in the event of a crash.
Consequence: A failure of the front air bags or seat belt pretensioners to deploy in the event of a crash necessitating deployment increases the risk of injury to the driver and front passenger.
Remedy: GM will notify owners, and dealers will reflash the SDM software. Vehicles that have had a previous air bag deployment will have the SDM replaced. These repairs will be performed free of charge. The recall began on August 4, 2017. Owners may contact Buick customer service at 1-800-521-7300, Cadillac customer service at 1-800-458-8006, Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 17287.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 17V307000
2017-05-09
General Motors LLC (GM) is recalling certain 2016-2017 Chevrolet Spark vehicles. In the event of a crash, if a young child is seated improperly and not wearing a seat belt while in the front passenger seat, deployment of the front passenger air bag may injure the occupant's neck. As such, these vehicles fail to comply with the requirements of Federal Motor Safety Standard (FMVSS) number 208, "Occupant Crash Protection."
Consequence: In the event of a crash with a frontal air bag deployment, an unbelted child in the front passenger seat has an increased risk of injury.
Remedy: GM will notify owners, and dealers will replace the passenger air bag module, free of charge. The recall began July 5, 2017. Owners may contact GM customer service at 1-800-222-1020. GM's number for this recall is 17199.
AIR BAGS:FRONTAL · 16V651000
2016-09-08
General Motors LLC (GM) is recalling certain model year 2015-2017 Chevrolet Silverado 2500 HD, 3500 HD, Tahoe, Suburban, GMC Sierra 2500 HD and 3500 HD, GMC Yukon, GMC Yukon XL, Cadillac Escalade and Cadillac Escalade ESV vehicles and 2014-2017 Chevrolet Corvette, Silverado 1500, Trax, Caprice Police Pursuit Vehicle, GMC Sierra 1500, Buick Encore, and 2014-2016 Buick Lacrosse, Chevrolet Spark EV and SS vehicles. In the affected vehicles, certain driving conditions may cause the air bag sensing and diagnostic module (SDM) software to activate a diagnostic test. During this test, deployment of the frontal air bags and the seat belt pretensioners would not occur in the event of a crash.
Consequence: A failure of the front air bags or seat belt pretensioners to deploy in the event of a crash necessitating deployment increases the risk of injury to the driver and front passenger.
Remedy: GM will notify owners, and dealers will reflash the SDM software. Vehicles that have had a previous air bag deployment will have the SDM replaced. These repairs will be performed free of charge. The recall began on October 13, 2016. Owners may contact Buick customer service at 1-800-521-7300, Cadillac customer service at 1-800-458-8006, Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 16007.
Fuel economy (EPA)
City
128MPGe
Highway
109MPGe
Combined
119MPGe
Fuel
Electricity
Capability & size
EPA class
Subcompact Cars
Wiper blades
EV continued on second generation platform through 2016
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2016 Chevrolet Spark EV Electric Motor and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.