NHTSA owner reports · September 18, 2026 snapshot.
Engine complaints
182 reportsClear category filterMileage unknown · Sep 26, 2025
Engine
Thousands of 2014-2017 Chevy Volt owners are having issues where the EGR Valve malfunctions and the engine shuts down. The Volt's EGR valve can cause the car to shut down by blowing the "walk home" fuse. This is a safety issue. In many cases cars are in the shop for months because the part is on "backorder". That's my situation…
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Thousands of 2014-2017 Chevy Volt owners are having issues where the EGR Valve malfunctions and the engine shuts down. The Volt's EGR valve can cause the car to shut down by blowing the "walk home" fuse. This is a safety issue. In many cases cars are in the shop for months because the part is on "backorder". That's my situation-- dealer just told me it's a $2800 repair job, but the part is on "backorder". The car only has 49K miles. Many threads on reddit with hundreds of comments / upvotes: [XXX] / [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11690014
Mileage unknown · Sep 26, 2025
Electrical SystemEngineFuel/propulsion System
EGR Valve failed in this vehicle <55,000 miles. The EGR valve has an electronic component that, when fails, can cause the car to shut down by blowing the "walk home" fuse. This is a safety issue. This is a well documented problem (internet) and Chevrolet refuses to fix it, leaving the owners with an expensive replacement quo…
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EGR Valve failed in this vehicle <55,000 miles. The EGR valve has an electronic component that, when fails, can cause the car to shut down by blowing the "walk home" fuse. This is a safety issue. This is a well documented problem (internet) and Chevrolet refuses to fix it, leaving the owners with an expensive replacement quoted at $3900 (Sept 2025). Recommend that it be covered by the emissions warranty, which was recently extended to 150,000 miles and 8 years for other problematic emissions components. An electric vehicle that cannot be driven because an EGR valve is faulty - it's a joke.
NHTSA ODI #11689998
Mileage unknown · Sep 18, 2025
Electrical SystemEnginePower Train
My 2017 Chevrolet Volt is experiencing "a malfunction involving the battery energy control module (BECM)" as diagnosed by the Davis-Moore dealership. This failure of the BECM has now caused "a reduced power mode, a no start condition, or a no charge condition". The car currently does not start or charge. My vehicle has be dia…
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My 2017 Chevrolet Volt is experiencing "a malfunction involving the battery energy control module (BECM)" as diagnosed by the Davis-Moore dealership. This failure of the BECM has now caused "a reduced power mode, a no start condition, or a no charge condition". The car currently does not start or charge. My vehicle has be diagnosed as needing a BECM replacement at a Chevrolet dealership. The vehicle is currently inoperable as it will not charge, it will not engage the electric drive mode, and it will not engage the range extender (engine). The car does not start. GM is showing that there is no active recall or special warranty for my vehicle, however, I believe special warranty N23243268 should apply.
NHTSA ODI #11688130
Mileage unknown · Aug 17, 2025
EngineFuel/propulsion SystemPower Train
I was driving my car from Houston to Dallas when I got the "reduced propulsion" message and a check engine light. When I first saw the reduced propulsion issue I thought it might be related to the BECM issue again since I had already experienced that problem before. In the last few minutes of my trip the AC started to get hot an…
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I was driving my car from Houston to Dallas when I got the "reduced propulsion" message and a check engine light. When I first saw the reduced propulsion issue I thought it might be related to the BECM issue again since I had already experienced that problem before. In the last few minutes of my trip the AC started to get hot and when I checked the coolant temperature I noticed it was around 240 - 255 F. I hadn't noticed it since there was no warning light for high temperature which I am used to with other cars. I'm not sure of the full extent of the issues yet, but I know for certain that the EGR valve has failed completely at about 71,500 miles. This is with very few miles on the actual ICE. I typically only use the ICE for a few hundred miles of driving each year. Fortunately for me, even though the CEL came on for the reduced propulsion I was able to reach my destination. However, when I went to leave, the car left me stranded as the ICE would shut down after a few minutes of running. The propulsion system is reduced and the engine becomes unavailable. Only the battery power will allow the car to drive. The F3 fuse in the EGR circuit blows if the engine is activated, and has happened multiple times already confirming the EGR issue. I have additional check engine lights that are a result of the EGR failure to circulate coolant properly. Below is a list of all the CEL codes that were pulled: P06DB P0030 P0031 P0403 P0405 P0443 P0458 P0489 P0597 P0598 P06DA P0AC4 P0135 P0AC4 P16E0 Looking into this issue I found that this is an one of the most common failures in the Chevy Volts but is no longer covered under the vehicle warranty and no bulletins posted for an extended warranty other than the BECM failure. This failure is so prevalent that I am surprised it is not.
NHTSA ODI #11681144
Mileage unknown · Jun 30, 2025
EngineFuel/propulsion System
Portion message car stalled on hey
NHTSA ODI #11670250
Mileage unknown · Jun 28, 2025
Engine
EGR Valve stop functioning, which caused Service not available engine check light on. This is a hybrid plugin, when battery is low, it is dangerous is Gas Engine not functioning. This EGR Valve is super expensive, the fix (Parts and Labor) is over $3300. The car milage was only a little over 58800 miles. Without getting this rep…
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EGR Valve stop functioning, which caused Service not available engine check light on. This is a hybrid plugin, when battery is low, it is dangerous is Gas Engine not functioning. This EGR Valve is super expensive, the fix (Parts and Labor) is over $3300. The car milage was only a little over 58800 miles. Without getting this repaired, the emission inspection will not be passed in Virginia.
NHTSA ODI #11669995
Mileage unknown · Jun 27, 2025
Electrical SystemEnginePower Train
My experience required me to tow my 2017 Chevy Volt from a parking garage, where the BECM died, to 2 different dealerships back and forth to my home. I have been charged over $1,000 in towing and diagnostics at my local dealerships. As usual they informed that I need a new $10k battery. I did my own research and the error codes …
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My experience required me to tow my 2017 Chevy Volt from a parking garage, where the BECM died, to 2 different dealerships back and forth to my home. I have been charged over $1,000 in towing and diagnostics at my local dealerships. As usual they informed that I need a new $10k battery. I did my own research and the error codes (U2603, U2604, U2605, U2606, U2617, U2618, U2619, U2620, U2621, U2622, U2623, U2624 and P1E00) clearly indicate that my BECM failed. I was able to check the health and status of the traction battery and it functioning correctly. On my 3rd trip to my local dealership service department with the Special Coverage Program N232432680 in hand, the dealership informed me that yes my BCM had failed and there was a Special Coverage Program for 2016-2019 Chevy Volts, but that MY VIN NUMBER WAS NOT COVERED. There were a limited number of VINS that received warranty extensions for BECM, but mine was not.
NHTSA ODI #11669821
Mileage unknown · Jun 10, 2025
Electrical SystemEngineFuel/propulsion System
While driving the vehicle, the car shut down. Thankfully I was coming to a yield at a round about after exiting the Interstate. I was finally able to get it to restart and proceeded on my way. If this had happened on the Interstate myself, and other drivers would be at risk due to unassisted steering and braking. I also have exp…
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While driving the vehicle, the car shut down. Thankfully I was coming to a yield at a round about after exiting the Interstate. I was finally able to get it to restart and proceeded on my way. If this had happened on the Interstate myself, and other drivers would be at risk due to unassisted steering and braking. I also have experienced intermittent periods of "Reduction of Power" while on the interstate and other 55MPH plus highways. This presents a hazard to myself and other drivers as well. These issues ARE covered for similar vehicles under Special Warranty Coverage N232432680 as required by NHTSA on March 6, 2024. My vehicle also exhibits all of the primary symptoms described in that coverage, but GM claims that my vehicle is NOT covered. CEL is on. Can't charge condition Reduced power No start condition
NHTSA ODI #11666037
Mileage unknown · Jun 9, 2025
Engine
My 2017 Volt reported a "Propulsion Power is Reduced" message on the display. When I took the car to the dealership for service, they stated that a new EGR valve was needed. The part alone is $1847. The total service with labor would have been over $3000. Looking online, it is a very common issue for the gen 2 Volts. Unfort…
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My 2017 Volt reported a "Propulsion Power is Reduced" message on the display. When I took the car to the dealership for service, they stated that a new EGR valve was needed. The part alone is $1847. The total service with labor would have been over $3000. Looking online, it is a very common issue for the gen 2 Volts. Unfortunately, the dealership is saying this repair is not covered under warranty.
NHTSA ODI #11665710
Mileage unknown · May 28, 2025
EnginePower Train
There is a part that fails on a lot of GM vehicles due to getting clogged (an EGR valve). It prevents the vehicle from reaching high speeds on the highway and can fail while driving (which happened to me). I could have lost control of the vehicle on the highway and crashed or gotten rear-ended. GM refuses to pay for repairs…
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There is a part that fails on a lot of GM vehicles due to getting clogged (an EGR valve). It prevents the vehicle from reaching high speeds on the highway and can fail while driving (which happened to me). I could have lost control of the vehicle on the highway and crashed or gotten rear-ended. GM refuses to pay for repairs involving this part despite so many people reporting the issue that they needed to do another production run of the part after discontinuing it. Here are many others that experienced this problem: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA ODI #11663386
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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