2011-2019 Volt & Ampera Fuse Box: Decoding Failures, TSBs, and Programming Myths

Symptoms of a Failing Fuse Box

Diagnosing a faulty fuse box can be tricky, as symptoms often mimic other electrical problems. It's important to distinguish between a single blown fuse and a failure of the entire fuse box assembly.

Symptoms of a Bad Fuse Box Assembly:

• Multiple, Unrelated Electrical Failures: Several different systems acting up at once (e.g., radio, lights, and power windows failing intermittently) can point to a problem with the main power distribution in the fuse box.
• Repeatedly Blowing Fuses: If a specific fuse blows repeatedly even after replacing it, it could indicate a short circuit in that component's wiring. However, if multiple different fuses blow, it may suggest an internal short within the fuse box itself.
• Visible Damage or Corrosion: A visual inspection is key. Look for signs of melting plastic around the fuse terminals, discoloration, or a white or greenish powder (corrosion) on the contacts. This can be caused by water intrusion or a loose connection creating heat.
• Burning Smell or Clicking Sounds: A strong plastic or electrical burning smell from under the hood is a serious red flag. Rapid clicking sounds from the fuse box can indicate a relay is failing or chattering due to unstable voltage.
• Sudden Loss of Power While Driving: A critical internal failure can cause the vehicle to lose all 12V electrical power suddenly, potentially leading to a stall or a no-start condition.

Symptoms of a Single Blown Fuse:

If only one specific component has stopped working, it is more likely a single fuse has blown. This is a protective measure. Common examples include:

• Headlights or taillights not working.
• Radio or infotainment screen is dead.
• Power windows, door locks, or power outlets are non-functional.
• The HVAC blower fan won't turn on.

Known Issues, TSBs, and Recalls

Several official service bulletins and customer satisfaction programs relate to the fuse box and associated electrical systems in the Chevrolet Volt. These are critical for diagnosis.

Generation 2 (2016-2019 Chevrolet Volt)

• TSB 21-NA-116: MIL Illuminated and Open Fuse: This bulletin addresses an issue where a short circuit in the Exhaust Gas Recirculation (EGR) valve or its wiring can cause fuse F3UA in the underhood fuse block to blow. This will illuminate the Malfunction Indicator Lamp (MIL) and may set codes like P0030.
• Service Update 16017: Misaligned Battery Cable: On some 2016-2017 Volts, the positive battery cable was misaligned at the underhood fuse block. This poor connection could lead to electrical arcing, heat, and potential damage to the fuse block terminal. The fix involves inspecting and properly seating the cable.

Generation 1 (2011-2015 Volt & 2012 Ampera) and General Issues

• Customer Satisfaction Program 16185 (2017 Models): Though for early Gen 2, this is relevant. A faulty high-voltage interlock connector or a blown 15A fuse in the high-voltage disconnect relay assembly could cause a no-start or loss of propulsion. The fix involved reprogramming the control module and replacing the fuse if needed.
• Parasitic Battery Drain from OnStar: On Gen 1 models, a common cause of a dead 12V battery is a malfunctioning OnStar module that fails to shut down. Before replacing the fuse box for battery drain issues, try pulling the OnStar fuse (typically F9 in the driver-side instrument panel fuse box) to see if the drain stops.
🎬 See: How to test parasitic draw using voltage drop

Programming, VIN Matching, and Immobilizer

This is the most important factor for buyers of used parts. You can safely install a compatible used fuse box without worrying about anti-theft systems or dealer visits. The vehicle's immobilizer system is tied to the Body Control Module (BCM) and Engine Control Module (ECM), not the fuse box.

Buying a Used Fuse Box: What to Look For

A used OEM fuse box is an excellent, cost-effective choice for this repair. Since it doesn't require programming, it's a simple swap. Here’s what to inspect:

• Match the Part Number: This is the most critical step. There are different fuse boxes for Gen 1 and Gen 2, and special versions for California PZEV (NU6) models. Ensure the part number on the used unit matches your original exactly.
• Inspect for Physical Damage: Check for any cracks in the plastic housing or broken clips.
• Check for Heat Damage or Arcing: Look closely at the main battery connection stud and all fuse terminals. There should be no signs of melting, black marks from arcing, or discoloration. Evidence of heat points to a previous issue that may have damaged the internal circuits of the box.
• Examine for Corrosion: Look for any white, green, or blue crusty buildup on the terminals or internal pins. A clean, corrosion-free fuse box is essential for reliable performance.
• Buy from a Reputable Source: Purchase from a recycler who offers a warranty and has inspected the part.

Vehicle and Part Number Compatibility

Fitment is split between two generations and special emissions packages. Always confirm your vehicle's year and options before buying. The RPO code 'NU6' for PZEV California Emissions can be found on the silver Service Parts Identification sticker, usually located in the glove box or trunk.

This list is not exhaustive. Part numbers can be superseded. Always verify compatibility by matching your original part number or consulting a dealer with your VIN.

Replacement Cost

Replacing the underhood fuse box can vary in cost depending on the source of the part. Since no programming is required, DIY or using an independent shop are great options.

Frequently Asked Questions (FAQ)