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Hi Everyone, long time lurker, first time poster on the forum. I've enjoyed my 2013 Volt for many years and I have learned so much about my car from the great folks here, so thanks a ton!

I'm hoping the experts here can answer a question I'm running into. Problem is that my Volt doesn't charge - yellow light upon plugging in, doesn't turn green, eventually just goes out. Car displays "Unable to Charge" message and "Reduced Propulsion Power" and check engine light is on. Bad news right? Same news with both L2 and L1 EVSE.

The dealer said the problem was loss of isolation, couldn't pinpoint where, and reprogrammed the HPCM and cleared the codes, hoping that might work. It didn't. Same problem happened as soon as I plugged in after driving home from the dealership. I drove straight back.

This time, the dealer says the problem is the "drive motor battery charger". The tech explained that it's the thing that inverts the power from 240 VAC to 360 VDC to charge the hybrid battery, and it needs to be replaced at a huge cost! The car's 3-year warranty is over, but I'm happy because the 8-year Voltec warranty is still running.

The problem however is that the dealer says the "drive motor battery charger" isn't covered by the Voltec warranty. They can't give me a reason why, they just say it isn't. I called GM and they confirmed it isn't covered, but they can't say why either. Just that it isn't, too bad so sad, file is closed.

Here's my question: the Voltec warranty covers the "Traction Power Inverter Module (TPIM)" and also the "on-board charger". It seems to me that the "drive motor battery charger" is at least one of those things -- it inverts power and it charges. Which is it? Or is GM correct that it's a totally different thing and not covered?

It's a lot of money, and if I have to pay I will, but only if I really have to. Thanks for sharing your knowledge!
 

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High Voltage components are covered, except when the dealer decides they aren't. Ignorance, or a profit opportunity. Review the warranty language, and then have them do the same with you.
 

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Here's my question: the Voltec warranty covers the "Traction Power Inverter Module (TPIM)" and also the "on-board charger". It seems to me that the "drive motor battery charger" is at least one of those things -- it inverts power and it charges. Which is it? Or is GM correct that it's a totally different thing and not covered?
If you have documentation showing that the on-board charger is covered, that is the same thing as the "drive motor battery charger". Do a search at GMPartsDirect.com for "charger" and it will show you only one non-EVSE "charger". I'd call GM again and get a different agent.
 

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Find a better dealer, and keep complaining to GM corporate. The internal battery charger is definetly covered by the Voltec warranty.
 

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You should be covered unless the warranty does not apply to you for some reason such as you are over the Voltec warranty mileage limit or you bought the car with a salvage title, etc.

You just haven't talked to someone yet who knows what they are saying. Keep trying, and be insistent. No GM employee ever got fired for saying something isn't covered by the warranty, so if they don't know, they always start with that answer.
 

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This time, the dealer says the problem is the "drive motor battery charger". The tech explained that it's the thing that inverts the power from 240 VAC to 360 VDC to charge the hybrid battery, and it needs to be replaced at a huge cost! The car's 3-year warranty is over, but I'm happy because the 8-year Voltec warranty is still running...
That is really shameful how they are treating Volt customers.

I had to get my charger replaced as well. I believe it was done under the Voltec warranty.

Post/thread here: https://gm-volt.com/forum/showthrea...-charging-but-it-is-not&p=4289185#post4289185


00822799689CHARGER DEVICE, DRIVE ELECTROMOTOR BATTERY (SEE INTO GROUP 02.000 "DRIVE BATTERY CHARGER" DETAILED GRAPHIC VIEW)

https://www.chevynorthcountry.com/parts-and-service/warranty-information/volthybrid-warranty/
 

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What is not covered is the EVSE cable. Some people call these a charger and they are not. They are just a communication box with car plug (the J1772) and a 120 volt wall outlet plug.

The dealer should know the difference.

You need to escalate this or find another dealer assuming that you are under 100,000 miles.
 

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The onboard charger is covered. If you live in CA you get 150,000 miles. Go to another dealer.
 

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Yep the similar nonesense I just wen tthrough with the harness between the charge port and control module. GM said no, I called, still NO and yet on page 16 all high voltage wires are covered. I had the director of service open a case to GM, they approved in 2 days and dealer wrote me a refund check in 1 day. It is indeed a game between GM and the dealer it seems. Be persistent, read the warranty book, go to the dealer and make them convince you otherwise. I was lucky to do it over the phone and was ready to go to the dealer gen mgr and then to district attorney locally if I had to.
 

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Discussion Starter #10
Hey everyone, I really appreciate the solid help with your responses. Let me tell you what happened, and also what is still happening.

Based on your responses, since GM had slammed the door shut on me, my last resort was to return to the service manager and ask why they believed the on-board charger wasn't covered when it was written in black and white in the warranty language. He sounded surprised that it was written this way, and he went to look at the warranty himself. Funny that he hadn't done this before refusing warranty coverage, but whatever. Happily, he came back to me and confirmed what everyone above said, which was that it was covered. He said GM's internal warranty codes were the opposite of what the manual said, which caused confusion at GM, but whether you believe him or not, I got my Volt back with a replaced charger as well as lots of passed tests to verify isolation, etc.

All good, right? Happy ending? Well...

I drove the Volt home, plugged in the EVSE nervously, saw the green light and 2 honks for delayed charging. All good so far. I went to check the car a few minutes after the charging *should* have started, but no green light, no yellow light, nothing. Uh oh. I unplugged and reinserted the EVSE, yellow light only, no charge. "Unable to Charge" "Reduced Propulsion" with MIL light. Back to square one. Man was I mad! I attached my OBD II bluetooth scanner, and saw code P0AF8 as a "historical" code. Not an active code, but it's there at least.

Then this morning, I start up the car to return it to the dealership (3rd time now!), and it starts up on battery, no codes, display reads "0 vehicle messages", no MIL, perfectly normal. What?! Can't be! I move about 10 feet, then go back to the EVSE, turn the car off, then plug in the EVSE again since the battery is only around 40% SOC. The light goes Yellow, then Green with a happy honk. I'm thinking that maybe the code resolved itself. All good, right?

Not so much. After several seconds I return to the car and the green light is now off. No charge. I unplug the EVSE, and I'm back to Reduced Propulsion with MIL. The car's back at the dealership now, and the service guy wasn't happy to see me again for sure.

I really like my Volt, I really do. But I'm so nervous about trusting it. I've read another post on these forums (#14925 - sorry it won't let me post links for some reason) where WopOnTour gave a nice summary of how to fix it, but I'm nervous about the dealer coming back and saying something else like my EVSE must be causing this, or maybe the charge receptacle needs replacement and this isn't covered by warranty, or something else that pushes everything back on me again.

I'll let you know how it goes, but thanks for your support so far! You're the best!
 

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Thanks for the update and good luck with the current fix. I predict you will have a better experience this time. Since they agreed to cover the first fix, and this is pretty obviously part of the first fix, I don't think they will try to weasel out this time.
 

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Discussion Starter #12
Hi everyone, my Volt is fixed, I'm happy to report. The tech accessed the battery relay assembly, which connects the high-voltage battery to the car. It was fried -- some switches were fused closed and there was a burned smell from some of the contactors. They replaced it - covered by Voltec warranty - and all works well now.

There is a great video at http:[slash][slash]insideevs.com[slash]chevrolet-volt-battery-deep-dive-2-hour-video that teaches in huge detail all things battery-related, and at 1:42:55 the teacher reviews the components that attach to the relay, some of which the tech reported as kaput. The great thing is that I have an entirely new relay so every component is now fresh with no wear and tear or exhaustion so everything will hopefully last at least another five years.
 

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I believe that Oregon has a longer warranty on the battery etc. I believe 150,000 miles, than most other states...
 
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