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The real costs of keeping a Chevy Volt on the road

The release of the new, 2016 Chevy Volt is sure to bring a surge of used electric vehicles to the market as early adopters trade their older models in. Many of these cars are selling for a fraction of their original price, thanks in part to federal and state incentives that lowered the initial cost to the first owner, which opens these cars up to a whole new class of consumers. While the prices are getting attractive, potential buyers are still hesitant to buy a used EV due to uncertainty about service and repair costs, but there may be some good news on the horizon. The Chevy Volt comes with a battery warranty that is good for at least 8 years and 100,000 miles, but many of the Volts popping up on the market have passed that 100,000-mile mark. The threat of needing a new battery can be a deterrent, especially with some dealers quoting prices as high as $34,000 for a full "drive motor battery replacement." That sum is more than the MSRP of a 2016 model. Some of the fear of EV maintenance and repair comes from the mystery of the individual pieces that make up the drivetrain and charging system. If we take a look at the Volt in terms of analogs to a traditional internal-combustion vehicle, the outlook becomes a little more friendly. The Volt battery pack consists of three lithium-ion modules in a T-shaped arrangement, each of which can be serviced individually. Module 1 is made up of 90 cells and corresponds to GM part number 22954462, which retails for $3,258.33; module 2 is made up of 72 cells and corresponds to GM part number 22954463, which retails for $2,930.00; lastly, module 3 is made up of 125 cells and corresponds to GM part number 22954464, and retails for $4,933.33. These part numbers have been added to the dealer order systems but have not shown up in the distribution centers at this time. Although all three of the modules add up to a fairly large $11,121.66 total and are still on hold for dealer ordering, the good news is that in most cases these battery cell modules do not need to be replaced. There are many other individual pieces mounted on the battery pack that are serviceable, such as the Battery Energy Control Modules (BECM) and the Battery Interface Control Modules (BICM). These modules control and monitor the battery packs and charging system and have been known to fail while the lithium-ion battery cells are not at fault. Some have been replaced under warranty, but if you are stuck buying one they run about $255 a piece for the part.

GM executive chief EV engineer says reducing cost of plug-in vehicles is 'huge priority'

As we know, another major automaker investing heavily in electrified vehicles is General Motors, and it's doing things much differently than rivals BMW, Ford or Nissan. The Chevrolet Volt extended-range EV is a modest seller at its $35,000 sticker price but a huge hit with owners. The Chevy Spark BEV, still in limited availability, puts smiley faces on its owners and drivers. The just-introduced Cadillac ELR, a sharp-looking, fun-driving $76,000 luxocoupe take on the Volt's EREV mechanicals, has admittedly low sales expectations. With this interesting trio in showrooms and much more in the works, the third vehicle electrification leader I collared for an interview at Detroit's North American International Auto Show (see #1 and #2) was Pam Fletcher, GM's executive chief engineer, Electrified Vehicles. ABG: Why do your EREVs need four-cylinder power to extend their range when BMW's i3 makes do with an optional 650 cc two-banger? "We designed [the Volt and the ELR] to go anywhere, any time" - Pam Fletcher PF: I get that question all the time: why not something smaller? You don't really need that much. You use the electric to its ability, then you just need to limp. But we designed those cars to go anywhere, any time, and we don't want their performance to be compromised. If you're driving through the mountains, we don't want you to be crawling up grades, or to be limited on any terrain. So it's optimized to be able to travel literally the biggest grades and mountain roads around the globe at posted speeds. Because what if you can't? Another good reason: when the engine is on, you have to run it wide open throttle, max speed, most of the time. And while we can do a lot with acoustics, and the ELR has active noise cancelation, a small-displacement, low cylinder-count engine at high speed, high load all the time isn't something you want to live with. That's how we came up with the balance we did among the key factors of performance, NVH [noise, vibration and harshness] and range. ABG: Where you go from here? Is the range-extender engine due for an update? PF: We know and love the current Volt, and there is still a lot of acclaim about it, so we think it's a good recipe. But we are heavily in the midst of engineering the next-generation car, which I think everyone will love and be excited about.

Fernando Alonso fails to qualify as Pagenaud takes Indy pole

Former Formula One world champion Fernando Alonso narrowly failed to qualify for the Indianapolis 500 on Sunday as France's Simon Pagenaud took pole position for the May 26 race. Kyle Kaiser beat out Alonso for the final spot in the 33-car field when he finished third, one spot ahead of the Spaniard, in a six-car shootout that determined the Indy 500's last row. The 23-year-old Kaiser, the last driver to take the track, averaged 227.372 mph for his four laps, a mere 0.019 mph ahead of Alonso's 227.353 mph average in the McLaren-prepared Chevrolet. "We never surrendered. We kept trying," Alonso, 37, told reporters after a tough week at the famed speedway. The Spaniard crashed his Chevrolet in practice on Wednesday and missed nearly two full days of practice while a back-up car was prepared. Then he tried five times on Saturday to qualify, puncturing a tire on the first attempt. Alonso had a completely new set up for Sunday's shootout but could not get the speed he needed to qualify. "I think the car felt better today than what we had yesterday. (So I am) happy with things we tried," he told reporters before learning he had not qualified. Pagenaud had a four-lap average speed of 229.992 mph to become the first Frenchman to take the pole since Rene Thomas in 1919. "It's just amazing," Pagenaud, who last week won the IndyCar Grand Prix on the track's road course, told NBC Sports. "Obviously last week was amazing, but this is even more special." He will be joined by Ed Carpenter (229.889) and Spencer Pigot (229.826) on the front row. But the Cinderella story belonged to Kaiser, the 33rd qualifier. "I don't think I can wrap my mind around what we just did," he said after bumping Alonso from the field. "This is all the credit to the team. They've been working non-stop trying to get this car ready for us and they did everything that we needed to get into this field." (Reporting by Gene Cherry in Raleigh, North Carolina; Editing by Ken Ferris)Related Video: Motorsports Chevrolet McLaren Racing Vehicles F1 IndyCar