Various Hydraulic Brake Issues that Could Be Seen on Electric/ Hybrid Vehicles and Possible DTC C05AD, C0580, or P05FF – 2016-2019 Chevrolet Malibu & Volt

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Service Bulletin Bulletin No.: 16-NA-286
Date: July, 2019
INFORMATION
Subject: Hydraulic Brake Performance Issues on Hybrid Vehicles, DIC Messages Displayed
and/or DTC C05AD, C0580 or P05FF Set
Brand: Model:
Model Year: VIN:
Engine: Transmission:
from to from to
Chevrolet Malibu 2016 2019
—
1.8L —
RPO LKN
—
Chevrolet Volt 2016 2019 1.5L —
RPO L3A
Involved Region or Country North America, Israel, South Korea
Condition Various hydraulic brake performance issues, possible DIC messages displayed and/or
DTCs may be set.
Cause
Kinks in metal lines or twisted flexible brake hoses, loss of brake fluid due to leaks,
reused hardware that should have been replaced, bent and distorted or damaged brake
caliper guide pins.
Correction Review the information within this Bulletin.
Overview
Brake system operation is comprised of mechanical
force being converted into hydraulic pressure by the
master cylinder which is regulated to meet braking
system demands by the pressure balance control
system and then delivered to the hydraulic brake wheel
circuits by the pipes and flexible hoses. The wheel
apply mechanical components then convert the
hydraulic pressure back into mechanical force which
presses linings against the rotating brake system
components.
– For information regarding any Conditions that may
not be corrected by using this Bulletin, refer to
Symptoms – Hydraulic Brakes and/or Hydraulic
Brake System Diagnosis in SI.
– For information regarding DTC C0580 Brake Pedal
Position Sensor Performance and DTC P05FF Brake
Pressure Sensor / Brake Pedal Position Sensor
Correlation, refer to Diagnostic Trouble Code
(DTC) List – Vehicle in SI.
Hydraulic Brake Conditions That May
Occur on Hybrid Vehicles
The following are examples of some conditions that
may occur on the hydraulic brake systems of Hybrid
vehicles.
Kinked Metal Brake Line
4565441
This example shows a misrouted front brake line,
resulting in kinking from hitting the shock tower when
the wheel is turned. This condition may cause reduced
brake fluid apply pressure to the wheel resulting in
brake performance issues. DTC C05AD Brake
Blending System Performance may set.
Page 2 July, 2019 Bulletin No.: 16-NA-286
Repair the kinked metal brake line. Refer to Brakes >
Hydraulic Brakes > Repair Instructions in SI.
After the repair, if DTC C05AD is still set, refer to DTC
C05AD Brake Blending System Performance in SI.
Rubber Brake Hose Rubbing on Tire/Wheel
Assembly
4565442
The brake hose is misrouted causing the hose to rub on
the front tire, eventually resulting in a loss of brake fluid.
4565584
The misrouting may be caused by the anti-rotation
bracket not properly seated into the retaining hole, or
the hose is not otherwise properly secured resulting in it
making contact with the rotating tire/wheel assembly.
Replace and properly secure the brake hose. Refer to
Front Brake Hose Replacement or Rear Brake Hose
Replacement in SI.
Twisted Brake Hose at Master Cylinder
4565443
4565585
Perform a visual inspection of the flexible brake hose at
the master cylinder for any kinks or twisting as shown.
This condition may cause reduced brake fluid apply
pressure to the wheels resulting in brake performance
issues.
Replace the flexible brake hose at the master cylinder.
Refer to Brakes > Hydraulic Brakes > Repair
Instructions in SI.
Bulletin No.: 16-NA-286 July, 2019 Page 3
Bent or Cracked Brake Fluid Bleeder Valve
4565444
Each brake caliper has a brake fluid bleeder valve. A
visual inspection may show that any of the front or rear
brake fluid bleeder valves have been bent or cracked. A
possible cause is road debris impact.
If this condition is encountered, replace the brake fluid
bleeder valve.
Brake Caliper Guide Pins
The purpose of the brake caliper guide pins is to align/
guide the proper angle for how the brake pads meet the
rotor in order to ensure correct and complete
application.
4565587
View of a damaged brake caliper guide pin.
Page 4 July, 2019 Bulletin No.: 16-NA-286
Important: The MY2016-2019 Malibu and Volt brake
caliper guide pins have several design differences
and different removal and installation procedures.
When servicing, refer to the applicable Service
Manual information.
If the brake caliper guide pins are suspected of causing
a brake performance condition, they have to be
removed to perform a visual and functional inspection
and to determine if any of the following conditions exist:
– Bent guide pins
– Corrosion
– Damage
– Distortion
– Grooves
– Lack of high temperature lubrication
– Looseness in the brake caliper mounting bracket
– Lower guide pin bushing damaged or missing
– Missing or improperly seated guide pin seal
– Restricted caliper guide pin movement
– Split or torn guide pin boots
– Seized or binding caliper guide pins
4565586
– Uneven brake pad contact/wear on the brake rotor.
⇒ MY2016-2019 Malibu: If any of these conditions
are observed, replace the brake caliper guide pins.
Refer to Front Brake Caliper Guide Pin
Replacement or Rear Brake Caliper Guide Pin
Replacement in SI.
⇒ MY2016-2019 Volt: If any of these conditions are
observed, replace the brake caliper guide pins.
Refer to Front Brake Caliper Replacement or
Rear Brake Caliper Guide Pin Replacement
in SI.
Brake Fluid Leak at Caliper Brake Hose to
Caliper
Important: On Malibu vehicle applications, the
brake hose caliper crush washers are also
identified as brake hose fitting gaskets. On Volt
vehicle applications, the sealing washers are also
identified as brake hose fitting gaskets. They can
only be used ONE time. When servicing, always
discard them and replace with new ones.
4565445
The brake hose caliper crush washer may exhibit a
distorted oval shape and witness lines which indicate
multiple use and may result in a brake fluid leak.
4565446
Important: When tightening the brake hose caliper
crush washer bolt, make sure to finger tighten the
bolt first to avoid cross threading when reinstalling.
Bulletin No.: 16-NA-286 July, 2019 Page 5
The brake fluid leak may also be caused by the brake
hose caliper crush washer bolt being cross-threaded
and retightened during installation.
⇒ If either of these conditions are encountered, refer
to Front Brake Hose Replacement or Rear Brake
Hose Replacement in SI.
⇒ If the hydraulic brake system requires bleeding due
to brake fluid loss, refer to Hydraulic Brake
System Bleeding in SI.
Version Information
Version 2
Modified July 18, 2019 – Made the Subject more concise, changed EV/Hybrid to Hybrid, added
Model Year 2018-2019 vehicles, inserted correct engines and RPOs, updated Involved
Region or Country, added Condition, Cause and Correction Table, clarified all of the text,
the proper steps to take to correct the conditions and the correct procedures to reference
in SI.

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