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Chevrolet

Volt (2011-2015)

High-voltage disable steps, no-cut zones, wait times, and firefighting quick-reference for safely dismantling the 2011-2015 Chevrolet Volt (PHEV), sourced from the OEM Emergency Response Guide.

PHEV · Plug-in Hybrid360V system
1

Wait

minute

after 12V cut before HV contact

Do not touch HV components until wait time has passed

FRONT

MID

HV pack

3

REAR

HV pack

12V12
HV pack zone12V batteryHV disable loop / service plug
  • 1 — Yellow cable-cut tag on the 12V positive cable — PRIMARY. Behind the left rear closeout panel / fuse-panel door. Cut each side of the tag; opens HV contactors.
  • 2 — 12V AGM battery — rear compartment under the load floor.
  • 3 — Manual Service Disconnect (MSD) under the center console box — backup; HV stays in pack after removal.

Schematic zones only — front/mid/rear are approximate. Verify exact locations against the OEM Emergency Response Guide.

First 10 minutes — pre-flight

Before you touch the vehicle. Run this once for every inbound EV or hybrid.

  1. Park downwind, on level ground

    If the pack is in thermal runaway it will vent flammable + toxic gas. Stay upwind. Block wheels.

  2. PPE on: HV-rated gloves, safety glasses, no jewelry

    Class 0 (1000V) rubber insulating gloves with leather over-protectors are the floor for any HV work.

  3. Walk-around: damage scan + signs of pack compromise

    Coolant pooling, white smoke/vapor, hissing, bulging panels, exposed orange cables, or chemical smell = stop. Treat as live and call OEM hotline.

  4. Confirm the vehicle is this card (year, make, model)

    Pack location and disable procedure differ between generations. Use the distinguishing visual to be sure.

  5. Locate your fire suppression and first-aid kit before starting

    Water is the only effective agent on Li-ion. Dry chemical, foam, and CO₂ will not stop a runaway. Have ≥250 gallons accessible.

HV Disable

  1. Primary
    Cut the 12V positive cable at the yellow First Responder cable-cut tag. Severing the low-voltage (12V) cable opens the high-voltage contactors inside the pack, de-energizing the HV system EXTERNAL to the 360V battery. Steps (OEM): 1) Press the Start button on the center instrument panel to turn the ignition OFF. 2) Cut the 12V positive cable at the yellow tag cut position. Cut through the red positive low-voltage cable on EACH SIDE of the tag to remove a section so it cannot inadvertently reconnect. After disabling 12V power, wait 1 minute for un-deployed airbag reserve energy to dissipate. NEVER cut the orange high-voltage cables.

    Yellow cable-cut tag is in the REAR compartment, behind the LEFT REAR closeout panel / behind the fuse-panel door (OEM-text). It wraps around the red 12V positive cable.

  2. Backup
    Remove the Manual Service Disconnect (MSD) to further disable the HV system inside the pack. The MSD physically interrupts the HV cables internal to the battery.

    MSD is underneath the center console box (OEM-text). A label there illustrates removal.

Note
OEM disable is CUTTING THE 12V POSITIVE CABLE at the yellow tag (this opens the HV contactors) — it is NOT a high-voltage cable cut. NEVER cut any orange high-voltage cable. GM (exact): "Do NOT cut the orange high voltage 360 volt cables. Cutting these cables can result in serious injury or death." CONTACTORS ALSO OPEN ON AIRBAG DEPLOYMENT (OEM-text): the HV contactors are commanded open whenever one or more airbags deploy, interrupting the 360V system. CRITICAL — the pack stays live internally (OEM-text): "No matter what disable method you have performed, always assume the high voltage cables and components contain high voltage." and "There is high voltage in the battery even if the MSD is removed." Never open, breach, or pierce the pack case. WARNING (OEM-text): "Do NOT cut into the vehicle until the 12V electrical system has been disabled. Cutting into the vehicle prior to disconnecting and isolating the 12V electrical energy sources may cause air bag deployment." CHARGING: if plugged in, first unplug the vehicle / remove charge power (charge port is on the left front fender, OEM-text). SCOPE: this card covers ONLY the 2011-2015 (Gen 1) Volt; the 2016+ Gen 2 Volt is a different vehicle and is NOT covered.

12V battery & SRS

12V location: Rear compartment, underneath the load floor (OEM-text). AGM lead-acid battery. The yellow cable-cut tag is behind the left rear closeout panel / behind the fuse-panel door.

OEM-text: severing the 12V cables causes the system to open the HV contactors. Disabling 12V power is the primary first-responder disable action. Cut the red 12V positive cable on each side of the yellow tag.

Pack & no-cut zones

Pack location: T-shaped pack inside the center tunnel AND under the rear seat (OEM-text). Mid + rear; NOT a flat underbody floor pack.

Pack chemistry: Lithium-ion (OEM-stated). The OEM guide refers to a Lithium-Ion Battery Chemistry MSDS but gives no cell maker/type or kWh. LG Chem manganese-spinel pouch cells per secondary sources only. NOT a NiMH hybrid pack despite the EREV marketing.1 source· 2×

cable color:Orange

Do not cut:

  • Orange-jacketed HV cables (entire routing). OEM: do NOT cut the orange high voltage 360 volt cables.
  • Center tunnel area AND the area under the rear seats (the 360V battery is installed here, per OEM)
  • HV battery internals / pack case (still contains high voltage after disable / MSD removal — never open the pack)
  • Roof rails near the lift-gate hinge (OEM lists side-curtain airbag inflators and lift-gate hold-open struts here)
  • Front seat back outboard area (OEM lists side airbags here)
  • B-pillar near the rocker (OEM lists the seat-belt retractor pretensioner; outboard front-seat lower frame houses an additional pretensioner)

Reinforcement (UHSS):

  • B-pillars
  • Rocker panels
  • Center tunnel (HV pack runs through it)
  • High-strength-steel safety cage (OEM: body structure is nearly 80% high-strength steel)

Pack piercing risk: The T-shaped pack sits in the center tunnel and under the rear seat (OEM) — not a flat underbody floor pack. Any tool, jack stand, or fork-truck tine that breaches the tunnel or the floor under the rear seat can pierce the pack, cause an internal short, and trigger thermal runaway. The pack remains internally live even after the 12V cut and MSD removal (OEM). Never breach the pack case.

Isolate damaged vehicle 50 ft from exposures.1 source· 1×

Open NHTSA recalls (5)

Live from NHTSA. Cross-check the VIN against nhtsa.gov/recalls before work.

Responder-relevant (2)

  • 18V397000 · MY 2013 · HYBRID PROPULSION SYSTEM

    General Motors LLC (GM) is recalling certain 2013 Chevrolet Volt vehicles. An update to the Hybrid Powertrain Control Module 2 (HPCM2) may have disabled the cell balancing function causing a low-voltage condition.

    Remedy: GM will notify owners, and dealers will reprogram the HPCM2, free of charge. The recall began July 24, 2018. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 18215.

    Filed

  • 15V145000 · MY 2011 · ELECTRICAL SYSTEM:IGNITION

    General Motors LLC (GM) is recalling certain model year 2011-2013 Volt vehicles manufactured August 25, 2010, to June 26, 2013. If the driver exits the vehicle without turning off the electrical system, the battery may drain low enough that the gasoline engine will automatically start itself to recharge the electric battery.

    Remedy: GM will notify owners, and dealers will update the engine management software to limit the time that the stationary vehicle can be left in the ON position, free of charge. The recall began April 15, 2015. Owners may contact Chevrolet customer service at 1-800-222-1020. GM's number for this recall is 14617.

    Filed

Show 3 other recalls
  • 23V516000 · MY 2013 · AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

    General Motors, LLC (GM) is recalling certain 2013 Buick Verano, Chevrolet Camero, Sonic, and Volt vehicles. The driver-side air bag inflator may explode during deployment due to a manufacturing defe…

  • 15V442000 · MY 2015 · STEERING

    General Motors LLC (GM) is recalling certain model year 2014-2015 Chevrolet Cruze vehicles manufactured November 8, 2013, to March 12, 2015, and 2015 Chevrolet Volt vehicles manufactured April 11, 201…

  • 13V271000 · MY 2012 · ELECTRONIC STABILITY CONTROL (ESC)

    General Motors (GM) is recalling certain model year 2012 Chevrolet Volt vehicles manufactured March 1, 2012, through April 17, 2012. Due to a brake pressure modulator valve problem, the vehicles do n…

Lift / jack points

Use OEM-designated frame/rocker lift points only. The HV pack runs through the center tunnel and under the rear seat (T-shape) — do NOT jack against, lift on, or pierce the pack case, the tunnel section, or the floor under the rear seat.

Fluid hazards

Coolant: Not stated in the OEM first-responder guide. (Gen 1 Volt uses a liquid battery-cooling loop per secondary sources; coolant type not given by GM.)

Electrolyte color: Not specified by GM. OEM-text: if cells reach high enough temperature they vent and release electrolyte, and the electrolyte is flammable. Color is general Li-ion knowledge (clear to pale yellow) — verify on-vehicle.

If burning, toxic vapors:

  • Hydrogen fluoride (HF)
  • Carbon monoxide
  • Volatile organic compounds (vented flammable electrolyte)
  • Metal oxides (manganese / nickel / lithium / cobalt / copper / aluminum)

Firefighting

Show firefighting details — Water (copious amounts). OEM: use copious amounts of water to cool the battery and extinguish the fire. OEM also states an ABC dry-chemical extinguisher will NOT extinguish a battery fire, and the battery on fire will not explode., ~1,500 galVerify

Agent: Water (copious amounts). OEM: use copious amounts of water to cool the battery and extinguish the fire. OEM also states an ABC dry-chemical extinguisher will NOT extinguish a battery fire, and the battery on fire will not explode.

Estimated volume: 1,500 gal

Reignition risk: 24 hours post-fire1 source· 1×

Thermal imaging: required during monitoring

Source

Chevrolet Volt Emergency Response Guide (PDF) →

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Show distinguishing visual

Compact 4-door hatchback; VOLT badging on the right-front and left-front fenders and the deck lid; charge-port door on the left front fender; unique LCD instrument-panel cluster and energy display. GM markets it as an Extended-Range Electric Vehicle (EREV).

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