I need advice because I feel like I'm running around in circles and am unsure what to do next.

Backstory: 2012 Volt, 122k miles, Los Angeles. It isn't passing SMOG so I cannot register the car. The check engine light keeps coming back with P1FFD and P1FFF (plus P1E00, and P0171 showed up once) along with the dash saying "Service High Voltage Battery System". The part that needs to be replaced is the coolant level sensor in the battery cooling system. GM has a bulletin about the solder joints failing inside this sensor.

What I've done so far:

Took it to the dealer. They reflashed the BECM and HPCM2 per the bulletin. Light came back 5 days later.

Took it back. They did a full diagnosis and their own tech wrote up that the surge tank assembly needs to be replaced. They said it wasn't covered by warrantee.

Opened a case with GM customer assistance. They talked to the dealer and referred me back to get it fixed. I did some research around this time about different warrantees and found out that California has a PZEV, which applies to cars less than 15 years old and less than 150,000 miles. My car satisfies that.

At the dealer, I had them run my VIN and confirm the car is PZEV certified. It is, which means the 15 year / 150k mile California emissions warranty applies, and I'm under both. They agree the sensor itself is a covered part.

Their denial: the sensor only comes as part of the surge tank assembly, the assembly includes non-covered parts, so the whole repair is customer pay. Quote is $1,800.

I got the denial in writing and escalated to the top manager at the dealership. No movement (I even asked him if it made sense, he said no). Filed a complaint with the Bureau of Automotive Repair today. Also sent a written escalation to Chevy customer assistance arguing the warranty follows the defective part and packaging doesn't void coverage.

Questions:

Has anyone had the dealer try not to complete their warrantee obligations? How did you get through this?

If you've dealt with BAR on a warranty complaint, how long did it take and did anything happen?

For the Volt owners: the standalone sensor is about $20 online. Has anyone replaced just the sensor at an independent shop?

Thanks

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