The 2016 Volt is a plug-in hybrid with a solid electric drivetrain but a problematic 1.5L range-extender engine that sees catastrophic failures. The Voltec transaxle is generally reliable, but the gas engine's piston ring design leads to oil consumption and complete rebuilds at surprisingly low mileage.
1.5L Range Extender Engine Piston Ring Failure / Oil Consumption
Common · high severity
Typical onset: 50,000-90,000 mi
Symptoms: Excessive oil consumption (1 quart per 1,000 miles or worse), Blue smoke on startup after sitting, Low oil pressure warning, Check engine light with P0301-P0304 misfire codes, Engine runs rough when range extender kicks in
Fix: This requires a complete engine teardown to replace piston rings, often combined with cylinder honing or bore work. Many shops recommend short block replacement instead of risking a ring job on worn bores. Expect 18-24 labor hours for a proper rebuild, 12-16 for short block swap. GM issued a warranty extension to 120k miles for some VINs, check eligibility first.
Estimated cost: $4,500-7,500
Transmission Oil Cooler Line Leaks
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Red fluid drips under front of vehicle, Transmission overheat warning on dashboard, Burnt transmission fluid smell, Reduced performance in mountain mode or under load
Fix: The metal cooler lines corrode where they pass near the subframe, particularly the lower line. Replacement requires removing the plastic undershield and dropping the subframe slightly for access. Use OEM lines—aftermarket ones crack at the fittings. 2.5-3.5 labor hours, fluid flush included.
Estimated cost: $600-900
Becm (Battery Energy Control Module) Communication Faults
Occasional · high severity
Symptoms: Propulsion power reduced message on DIC, Vehicle won't shift out of park, Traction battery won't charge from wall or engine, Check engine light with U0151 or U0293 codes, Sudden loss of all electric drive with gas engine running
Fix: The BECM controls high-voltage battery management and fails due to internal capacitor or circuit board issues. This is NOT a software reflash—module replacement is required. Located under rear seat area, requires disconnecting HV battery (orange service disconnect). 3-4 labor hours plus programming time. Must be dealer-programmed in most cases.
Estimated cost: $2,200-3,500
Transmission Mount (Torque Strut) Failure
Common · low severity
Typical onset: 70,000-110,000 mi
Symptoms: Severe clunk when switching between drive and reverse, Vibration through steering wheel when range extender starts, Visible sagging of engine/transaxle assembly, Metal-on-metal knock during hard acceleration
Fix: The upper torque strut mount (hydraulic style) fatigues and tears. The Volt's instant torque from electric motors accelerates wear. Replacement requires supporting the powertrain from below while swapping the mount. Use OEM or Westar brand—cheap mounts fail in 6 months. 1.5-2 labor hours.
Estimated cost: $350-550
Fuel System Problems from Stale Gas
Occasional · medium severity
Symptoms: Hard start or no-start when range extender tries to run, Check engine light with P0087 (fuel pressure low), Strong varnish smell from exhaust when engine runs, Fuel maintenance mode runs frequently, Rough idle and stalling when gas engine operates
Fix: Owners who drive electric-only for months develop varnished fuel injectors and clogged fuel filters. The in-tank pump can also fail from sitting in old gas. Full fix includes fuel system cleaning, injector replacement, and new fuel filter (integrated with pump module). Tank may need drop for pump access. 4-6 labor hours depending on fuel age and contamination level.
Estimated cost: $800-1,400
12V Battery Parasitic Drain
Occasional · medium severity
Symptoms: Dead 12V battery after sitting 3-5 days, Clicking when pressing start button but no ready light, Radio and climate settings reset frequently, OnStar/4G LTE module stays active continuously
Fix: The OnStar/communications module and BECM can draw excessive current when vehicle sits. If 12V battery is original (Group 47, under hood), replace it first—they're weak from factory. If drain persists, pull fuse 23 (OnStar) for testing. Module replacement needed if confirmed faulty. Diagnosis 1-2 hours, module swap 1 hour.
Estimated cost: $180-250 for battery, $600-1,200 if module replacement needed
Owner tips
Run the gas engine monthly even if you drive electric-only—fuel maintenance mode helps but isn't enough to prevent varnish buildup
Check oil level every 500 miles once past 50k miles; early detection of consumption can save you from a grenaded engine
Use Top Tier gas and keep tank above 1/4 full to minimize fuel system issues
Have the HV battery coolant changed at 150k miles—it's lifetime fill but degrades, causing cell imbalance and range loss
Verify any used Volt has the piston ring warranty extension applied (check with dealer by VIN) before purchase
Great commuter if you can verify the engine hasn't been rebuilt yet and budget $5k for the inevitable piston job—or find one still under the ring warranty extension.
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: AGM battery required; located in rear cargo area; auxiliary 12V battery for range extender engine starting
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Every control module on the 2016-2019 Chevrolet Volt — 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.
Electric Power Steering Control Module (EPSCM)2.5 hr R&Rdealer / factory tool +0.5 hr▸ programming details
📍 Integrated with steering column assembly, below instrument panel
🔧 GM SPS2 via GDS2/MDI or Techline Connect
⚠️ Steering angle sensor calibration required after replacement
Body Control Module (BCM)2.0 hr R&Rdealer / factory tool +0.8 hr▸ programming details
Remote Control Door Lock Receiver (RCDLR)0.8 hr R&Rdealer / factory tool +0.3 hr▸ programming details
📍 Behind rear interior trim, driver side
🔧 GM SPS2 via GDS2/MDI or Techline Connect
⚠️ Key fob programming required
Park Assist Control Module (PACM)0.8 hr R&Rrelearn only +0.2 hrwith rear park assist▸ programming details
📍 Behind rear bumper cover, center
🔧 Basic scan tool for sensor calibration
Driver Seat Control Module (DSCM)0.8 hr R&Rno codingwith power driver seat
📍 Under driver seat, mounted to seat frame
Rear Vision Camera Module (RVCM)0.5 hr R&Rno coding
📍 Integrated with rear liftgate handle assembly
⚠️ Standard equipment on Gen 2
Headlamp Control Module (HCM)0.5 hr R&Rno coding▸ programming details
📍 Engine compartment, behind driver side headlamp assembly
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 2015-2016 GMC Canyon and Chevrolet Colorado, and 2016 Chevrolet Volt vehicles. The driver's frontal air bag may improperly inflate during second-stage deployment in the event of a high speed crash.
Consequence: An improperly inflated air bag increases the risk of injury in a crash.
Remedy: GM will notify owners, and dealers will replace the driver's frontal air bag module, free of charge. The recall began November 8, 2017. Owners may contact Chevrolet customer service at 1-800-222-1020, or GMC customer service at 1-800-462-8782. GM's number for this recall is 17387.
Fuel economy (EPA)
City
43mpg
Highway
42mpg
Combined
42mpg
Fuel
Regular Gasoline
Capability & size
EPA class
Compact Cars
Wiper blades
Gen 2 Volt (2016-2019); sedan body style has no rear wiper
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 Volt 1.5L I4 Range Extender 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.