NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
182 reportsClear category filterMileage unknown · Nov 30, 2023
Engine
Chevy Volt's Exhaust Gas Recirculation (EGR) system valve and cooler The EGR system on these cars are faulty. I have had to take this car in multiple times related to the EGR. In Septemer 2023 car suddenly stopped on middle of highway putting my life in danger. At dealership Pohanka Chevy in Northern Virginia, I was told it was …
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Chevy Volt's Exhaust Gas Recirculation (EGR) system valve and cooler The EGR system on these cars are faulty. I have had to take this car in multiple times related to the EGR. In Septemer 2023 car suddenly stopped on middle of highway putting my life in danger. At dealership Pohanka Chevy in Northern Virginia, I was told it was the EGR valve, I had the EGR cooler replaced by the same dealership in 2023 so I took the car to Koons Chevy in Northern Virginia for a second opinion. The dealership indicated that this is very common problem with Chevy Volts and they said the parts are not available for it. Apparently the last customer waited 3 months. Currently the car will not run on the gas engine but only on the electric which is about 40 to 50 miles which makes it non useable for me. In addition, the car will not part emissions test rendering it against the law for me to use even if the engine was running. I reported this to Chevy corporate (case number XXX) and now it has been multiple months and nothing has happened except Chevy sending me a email every ten days indicating they do not have a part. They will not also give me a rental (I have to pay out of pocket and they will reimburse me which is something I cannot afford). Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, I took it to two chevy dealerships in Northern Virginia and one in Georgetown Delaware. They cannot correct the issue since there are no EGR valves. The car will not pass emissions test. The Chevy dealer I am using is Koons Chevy at Tysons Corner, Phone 703-448-7221 (POC was Johnathon) Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? Yes Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Check engine light I purchased this car brand new of the lot ($37K) and now saddled with something that is of no use INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATI
NHTSA ODI #11557618
Mileage unknown · Oct 17, 2023
Engine
Intermittent starting Had car towed to auto shop Auto shop stated that the B.E.C.M Board is going out Battery Energy Control Module G.M Has a class action lawsuit over this matter
NHTSA ODI #11550431
Mileage unknown · Oct 13, 2023
EngineFuel/propulsion System
As reported by the dealer the Battery Energy Control Module (BECM) has failed. Car initially did not start but then did start with a check engine light and a "Propulsion Power is Reduced" warning. Vehicle has approximately 56,500 miles. Car could have abruptly stopped or slowed considerably while driving. Chevrolet dealer is bl…
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As reported by the dealer the Battery Energy Control Module (BECM) has failed. Car initially did not start but then did start with a check engine light and a "Propulsion Power is Reduced" warning. Vehicle has approximately 56,500 miles. Car could have abruptly stopped or slowed considerably while driving. Chevrolet dealer is blaming the current UAW strike for complete lack of replacement parts. They also state there is no way to forecast a delivery date of the part. I am out a vehicle for an unknown amount of time with no promise that GM will reimburse me for out of pocket expenses for a rental vehicle.
NHTSA ODI #11549740
Mileage unknown · Oct 6, 2023
EngineFuel/propulsion SystemPower Train
Random no starts, engine turns on at random, won’t charge, car jerks, hesitation while driving, hard to climb mountain roads, Battery Energy Control Module Lost Communication With Hybrid/EV Battery Interface Control Module 1-12
NHTSA ODI #11548743
Mileage unknown · Jul 26, 2023
Engine
When the EV charge runs out and car turns on gas engine. Gas engine will run for a few minutes and then turn off with an error message on dashboard. Car will only drive safely for as long as you have EV power, which is a problem since the gas engine is used when the EV power runs out. Mine failed on an interstate, but I made i…
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When the EV charge runs out and car turns on gas engine. Gas engine will run for a few minutes and then turn off with an error message on dashboard. Car will only drive safely for as long as you have EV power, which is a problem since the gas engine is used when the EV power runs out. Mine failed on an interstate, but I made it to a safe place to stop only because I had a tiny bit of EV charge left due to my practice of using hold mode to save some battery power on long interstate drives. Service reported back that it is a faulty EGR valve and I am waiting to find out if they can even get the part in stock. GM is not adequately stocking these EGR valves. The failure rate from known manufacturing/design defects is higher than the rate that they restock them. These cars are not street legal when the EGR valve fails due to their inability to pass emissions testing since the EGR failure causes the service engine soon light to be on. An owner cannot renew the registration to legally drive the vehicle once the EGR valve fails, the whole car is undriveable without the part being available.
NHTSA ODI #11534578
Mileage unknown · May 7, 2023
Electrical SystemEngineFuel/propulsion System
When I first purchased the car (used around 30,000 miles), I began to have electrical and propulsion issues where the engine would turn off. After Chevy refused to warranty or lemon the car, eventually the electrical/hybrid issue repeated and caused cooling issues with the car and then water pump went bad. while chevy still refu…
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When I first purchased the car (used around 30,000 miles), I began to have electrical and propulsion issues where the engine would turn off. After Chevy refused to warranty or lemon the car, eventually the electrical/hybrid issue repeated and caused cooling issues with the car and then water pump went bad. while chevy still refused to fix the hybrid and battery issues, that continued issue and then the water pump failing from it then caused overheating that then broke the head gasket
NHTSA ODI #11520855
Mileage unknown · Feb 15, 2023
EngineFuel/propulsion SystemVehicle Speed Control
After the battery runs out, the engine loses propulsion and fails to run on gas. The car completely stalls in the middle of traffic. The speed drops from 70+ mph to 0. Extremely dangerous to myself and others. The issue suddenly appeared at the end of December 2022 during a long drive. The engine check light remains on and a war…
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After the battery runs out, the engine loses propulsion and fails to run on gas. The car completely stalls in the middle of traffic. The speed drops from 70+ mph to 0. Extremely dangerous to myself and others. The issue suddenly appeared at the end of December 2022 during a long drive. The engine check light remains on and a warning re: reduced propulsion power is displayed every time the car is turned on. Dealer is unable to fix the issue because they already have multiple cars with the same issue waiting for weeks to be repaired. Recently filed class action law suit suggests that this problem is caused by defective BCEM unit.
NHTSA ODI #11507401
Mileage unknown · Nov 30, 2022
EngineFuel/propulsion SystemPower Train
I have owned my 2017 Volt since November of 2016. I drive about 200 miles a week and currently my mileage is at 109,000 (9,000 miles PAST the warranty period). My car did not start one morning and had to have it towed to my local GM dealership. They diagnosed it with a bad BECM and a repair bill of $1,400. They have no estim…
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I have owned my 2017 Volt since November of 2016. I drive about 200 miles a week and currently my mileage is at 109,000 (9,000 miles PAST the warranty period). My car did not start one morning and had to have it towed to my local GM dealership. They diagnosed it with a bad BECM and a repair bill of $1,400. They have no estimated time on when the part will be shipped. It is unacceptable to not have an ETA for a critical part or the vehicle. I have read on many forums that the BECM is a known failure for the 2017 Volt.
NHTSA ODI #11495449
Mileage unknown · Nov 29, 2022
Electrical SystemEngineFuel/propulsion System
Vehicle started to lose power. Showed error messages "reduced power" after a series of "shift to park" messages when first starting. Had no propulsion power until several attempts to start vehicle. Once started engine would run but all electric propulsion was inoperable. Vehicle has become totally unreliable at approx 22,000…
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Vehicle started to lose power. Showed error messages "reduced power" after a series of "shift to park" messages when first starting. Had no propulsion power until several attempts to start vehicle. Once started engine would run but all electric propulsion was inoperable. Vehicle has become totally unreliable at approx 22,000 miles, sometimes starting and sometimes not. Power loss occurs while driving which is definitely a safety hazard if on the Interstate and minimum speed can't be maintained. Have taken vehicle to dealer where it was diagnosed as a defective "BECM" (I believe a master control module attached to the main propulsion battery). The dealer has ordered a replacement module but it's been four months with no sign of a replacement. Essentially I now have an unreliable and potentially unsafe vehicle with no sign of the manufacturer trying to facilitate repairs.
NHTSA ODI #11495368
Mileage unknown · Nov 27, 2022
Electrical SystemEngineFuel/propulsion System
Emergency warning messages appeared on 24 Aug 2022 and a day later vehicle was taken to Chevrolet dealer who first replaced a "section of the battery" and eventually verified a problem with the BECM (Battery Energy Control Module). Now (end Nov 2022) 3 months later no repair part has become available. Because we immediately took…
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Emergency warning messages appeared on 24 Aug 2022 and a day later vehicle was taken to Chevrolet dealer who first replaced a "section of the battery" and eventually verified a problem with the BECM (Battery Energy Control Module). Now (end Nov 2022) 3 months later no repair part has become available. Because we immediately took the vehicle to a dealer, we had no safety issues.
NHTSA ODI #11495029
NHTSA investigations
2PE23022 · Loss Of Motive Power Due To The Battery Energy Control Module
Opened Nov 29, 2023 · Closed Mar 3, 2025
Status: closed (inferred from source dates) · Electrical System; Electrical System:propulsion System; Electrical System:propulsion System:traction Battery:management System/energy Control Module (bms/becm)
On November 29, 2023, the Office of Defects Investigations (ODI) opened PE23022 to investigate allegations of a loss of motive power, including a stall, reduced power state, and/or a no start condition due to the Battery Energy Control Module (BECM) in model year (MY) 2016-2019 Chevrolet Volt passenger car vehicles manufactured by General Motors (GM). The BECM is located within the high voltage electric vehicle (EV) battery pack and monitors the temperature, current, and voltage of the high voltage battery cell groups. GM stated that the root cause was identified as an internal failure leading to a loss of communication within the BECM and does not pose a risk to motor vehicle safety. GM further stated that the failure cannot result in a complete stall, only a reduced power mode, no start condition, or a no charge condition. GM additionally stated that if these conditions occur, the driver will be warned via a Malfunction Indicator Lamp (MIL) and/or a reduced-propulsion message in the Driver Information Center (DIC). Data received and analyzed by ODI from all sources indicates that nearly all related BECM failures caused conditions aligning with GM’s predicted outcomes. Despite the large number of warranty claims, nearly all failures were not safety-related, i.e., not a stall or reduced power mode. ODI isaware of a single minor crash and no injuries or deaths. In March 2024, GM issued Special Coverage N232432680, which was mailed to consumers, addressing BECM failures in certain MY 2016-2018 Chevrolet Volt vehicles. This special coverage provides an extension of the warranty coverage for the BECM from 8 years / 100,000 miles to 15 years / 150,000 miles for all 2016-2018 Chevrolet Volts. Additionally, GM stated that replacement components are sourced from a different supplier and not susceptible to the failure. In view of the Special Coverage issued by GM, the existing warranty coverage already in place, and the low number of safety-related occurrences, ODI is closing this Preliminary Evaluation (PE). The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Additional source detail variants (3)
Electrical System
On November 29, 2023, the Office of Defects Investigations (ODI) opened PE23022 to investigate allegations of a loss of motive power, including a stall, reduced power state, and/or a no start condition due to the Battery Energy Control Module (BECM) in model year (MY) 2016-2019 Chevrolet Volt passenger car vehicles manufactured by General Motors (GM). The BECM is located within the high voltage electric vehicle (EV) battery pack and monitors the temperature, current, and voltage of the high voltage battery cell groups. GM stated that the root cause was identified as an internal failure leading to a loss of communication within the BECM and does not pose a risk to motor vehicle safety. GM further stated that the failure cannot result in a complete stall, only a reduced power mode, no start condition, or a no charge condition. GM additionally stated that if these conditions occur, the driver will be warned via a Malfunction Indicator Lamp (MIL) and/or a reduced-propulsion message in the Driver Information Center (DIC). Data received and analyzed by ODI from all sources indicates that nearly all related BECM failures caused conditions aligning with GM’s predicted outcomes. Despite the large number of warranty claims, nearly all failures were not safety-related, i.e., not a stall or reduced power mode. ODI isaware of a single minor crash and no injuries or deaths. In March 2024, GM issued Special Coverage N232432680, which was mailed to consumers, addressing BECM failures in certain MY 2016-2018 Chevrolet Volt vehicles. This special coverage provides an extension of the warranty coverage for the BECM from 8 years / 100,000 miles to 15 years / 150,000 miles for all 2016-2018 Chevrolet Volts. Additionally, GM stated that replacement components are sourced from a different supplier and not susceptible to the failure. In view of the Special Coverage issued by GM, the existing warranty coverage already in place, and the low number of safety-related occurrences, ODI is closing this Preliminary Evaluation (PE). The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Electrical System:propulsion System
On November 29, 2023, the Office of Defects Investigations (ODI) opened PE23022 to investigate allegations of a loss of motive power, including a stall, reduced power state, and/or a no start condition due to the Battery Energy Control Module (BECM) in model year (MY) 2016-2019 Chevrolet Volt passenger car vehicles manufactured by General Motors (GM). The BECM is located within the high voltage electric vehicle (EV) battery pack and monitors the temperature, current, and voltage of the high voltage battery cell groups. GM stated that the root cause was identified as an internal failure leading to a loss of communication within the BECM and does not pose a risk to motor vehicle safety. GM further stated that the failure cannot result in a complete stall, only a reduced power mode, no start condition, or a no charge condition. GM additionally stated that if these conditions occur, the driver will be warned via a Malfunction Indicator Lamp (MIL) and/or a reduced-propulsion message in the Driver Information Center (DIC). Data received and analyzed by ODI from all sources indicates that nearly all related BECM failures caused conditions aligning with GM’s predicted outcomes. Despite the large number of warranty claims, nearly all failures were not safety-related, i.e., not a stall or reduced power mode. ODI isaware of a single minor crash and no injuries or deaths. In March 2024, GM issued Special Coverage N232432680, which was mailed to consumers, addressing BECM failures in certain MY 2016-2018 Chevrolet Volt vehicles. This special coverage provides an extension of the warranty coverage for the BECM from 8 years / 100,000 miles to 15 years / 150,000 miles for all 2016-2018 Chevrolet Volts. Additionally, GM stated that replacement components are sourced from a different supplier and not susceptible to the failure. In view of the Special Coverage issued by GM, the existing warranty coverage already in place, and the low number of safety-related occurrences, ODI is closing this Preliminary Evaluation (PE). The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
Electrical System:propulsion System:traction Battery:management System/energy Control Module (bms/becm)
On November 29, 2023, the Office of Defects Investigations (ODI) opened PE23022 to investigate allegations of a loss of motive power, including a stall, reduced power state, and/or a no start condition due to the Battery Energy Control Module (BECM) in model year (MY) 2016-2019 Chevrolet Volt passenger car vehicles manufactured by General Motors (GM). The BECM is located within the high voltage electric vehicle (EV) battery pack and monitors the temperature, current, and voltage of the high voltage battery cell groups. GM stated that the root cause was identified as an internal failure leading to a loss of communication within the BECM and does not pose a risk to motor vehicle safety. GM further stated that the failure cannot result in a complete stall, only a reduced power mode, no start condition, or a no charge condition. GM additionally stated that if these conditions occur, the driver will be warned via a Malfunction Indicator Lamp (MIL) and/or a reduced-propulsion message in the Driver Information Center (DIC). Data received and analyzed by ODI from all sources indicates that nearly all related BECM failures caused conditions aligning with GM’s predicted outcomes. Despite the large number of warranty claims, nearly all failures were not safety-related, i.e., not a stall or reduced power mode. ODI isaware of a single minor crash and no injuries or deaths. In March 2024, GM issued Special Coverage N232432680, which was mailed to consumers, addressing BECM failures in certain MY 2016-2018 Chevrolet Volt vehicles. This special coverage provides an extension of the warranty coverage for the BECM from 8 years / 100,000 miles to 15 years / 150,000 miles for all 2016-2018 Chevrolet Volts. Additionally, GM stated that replacement components are sourced from a different supplier and not susceptible to the failure. In view of the Special Coverage issued by GM, the existing warranty coverage already in place, and the low number of safety-related occurrences, ODI is closing this Preliminary Evaluation (PE). The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
DP22005 · Pedestrian Alert Sounds
Opened Jan 27, 2023 · Closed Aug 7, 2023
Status: closed (inferred from source dates) · Electrical System:propulsion System
NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.
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