Gas Recirculation Valve (egr Valve) Problems of Chevrolet Volt - part 1

The engine light came on, but the car would run and so took it to the dealer. They determined that the egr valve had failed and would cost $2400 to repair. Apparently, this is a common failure point for generation 2 chevy Volts. If it might trigger a forced recall, I'd like to add this to the list.

See all problems of the 2016 Chevrolet Volt 🔎.

Brought car into Chevrolet dealership for intermittent “miss” when driving. Dealer diagnosed it needed an egr valve replaced at a cost of around $4,000. 00 which is a significant portion of the cars value.

See all problems of the 2017 Chevrolet Volt 🔎.

My egr system caused a check engine light. P0401 this is an extremely well documented issue on gen2 Volts, especially 2017 models. Simply searching "egr" on the Volt subreddit or forums returns hundreds of related threads. This issue can lead to a clogged egr valve, causing further damage. A temporary resolution is unplugging the egr valve, which I have not yet done. But this leaves the cel illuminated, and without daily scanner, I wouls not know if other issues arise, causing a significant safety hazard.

The egr valve clogged, causing a a servo to blow the f3 fuse, disabling the engine while driving. This occured suddenly while driving on a busy road with no shoulders. I managed to coast into a parking lot not too far away but I had no charge left in my battery. I could only get the engine to start back up for less than a minute at a time. I got my car inspected by Chevrolet and they confirmed they issue. Very shortly before the engine cut off, the car started jolting. There weren't any warning lights or error codes before this.

See all problems of the 2018 Chevrolet Volt 🔎.

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.

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. . Read more...

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.

Electrically actuated egr valve fails, it draws too much current and blows the f03 fuse (labeled “no walk home”) which has 4 other components on it, this causes “reduced propulsion” message, soon after the engine overheats due to one or more of the 3 other components that lost power, and the “engine not available” message appears and the vehicle loses all motive power. This syndrome is well documented in the gm-volt online forum. Additionally this vehicle has portions of the ev battery that failed, I am still waiting for battery parts to arrive and its been 4 months, many owners have waited between 1 and 2 years for the battery to be fixed, this contributed to this issue as the electric propulsion would have possibly been available if the warrantied battery was repaired within a reasonable timeframe. I was refused a service loaner. My recent contact with Chevrolet customer service suggested I rent a car, and they will reimburse $45 per day, however they insist I pay for it and when the repair is complete, they will reimburse me. There is a gentleman on the Volt forum who has laid out about $5,000 on rental cars for well over a year, and is finally reluctantly getting a buyback, but they depreciated the car but did separately make good on the rental reimbursement. Neither he nor I really want that result, we want the car repaired in a good faith effort, instead both battery parts and egr valves are in short supply. Currently the gm part is between $1400 and $2500 when in 2024 the same part was widely available for $240. I understand this is a bit rambling, but the context matters, and gm is dragging their feet on servicing the warranty liability they have. My tzev warranty is good until 2034 and they are actively trying to kill my car off to save the ongoing cost of servicing this warranty. They are also putting owners at risk. Please consider a battery recall and an egr valve recall. Regards, [xxx] information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Egr valve and egr cooler failure. Engine power was reduced and egr fuse kept blowing. Has code for egr flow failure/restriction. Check engine light remains on even when reset.

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.

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).

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.

The contact owns a 2018 Chevrolet Volt. The contact stated that while his wife was driving 60 mph, the message “power reduced” was displayed. The vehicle was taken to an independent mechanic who determined that the failure was due to the egr valve. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 51,000.

My chevy Volt went into reduced propulsion system power mode, the engine light came on and the vehicle stalled while sitting at a traffic light on [xxx] at [xxx] in tyler texas. Checking the computer and the complaints online I found that my 15 amp #03 fuse (no walk home) had blown. I replaced the fuse and the next day on [xxx] the same thing happened again after driving 30 miles. The vehicle stalled at an intersection outside of tyler texas. The egr valve is known to cause the fuse to blow, so I had no choice but to unplug the egr valve and replaced the fuse and has not blown the fuse since. This is both a safety issue and an emissions issue, but the replacement part cannot be found anywhere to purchase anymore so I am having to drive this vehicle with this ongoing safety issue. Due to the nature of the egr valve blowing the fuse all the time and that it affects the safety of the vehicle a nationwide recall needs to be done on these vehicles to force gm to start making the part again. This is a dangerous flaw that will cause the vehicle to stall and create a safety hazard. This has been ongoing for quite some time with these Volts, and something needs to be done about it ASAP. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Egr valve failure at highway speed of 70mpg on busy road with passenger and service dog in vehicle on a road trip (on ice not electric). This produces a reduced propulsion in the vehicle and it becomes unsafe to drive. The egr failure blew the 15a #3 fuse known as the "no walk home" fuse, so I needed to be towed to a parts store then unplug the egr valve to make it somewhere safe. It was a Sunday, so every dealership (in the va area at least) was closed. It is a well known/documented issue and the warranties have been extended, but only in a few states with the carb protections. There are no warnings, if I was not an adept driver, we could all be dead. I also became stranded ~six hours from my home and only ~eight thousand miles outside of warranty. The replacement part costs ~$1800 without labor - the most expensive egr valve the 60yr old parts employee at the dealership had ever seen, on a hybrid car which doesn't even truly require the part to operate or to pass emissions in some states. I think gm will help me with a goodwill repair in this case, as I have been a loyal chevy customer my entire life and Volt owner since 2013 - but that is not the norm, so please take action and extend warranty protection to all Volt owners like the becm issue.

P0401 error egr valve not receiving enough fuel.

Bad egr valve in 2017 chevy Volt, apparently a common problem. Received a check engine light, risk of reduced propulsion (creates risk of stalling and crashing on highway).

Yes this vehicle can be made ready for inspection upon request. According to the registered Chevrolet dealership who inspected my vehicle and gave me the diagnosis - the cars egr valve control board is shorting out fuse #3 which leads the car to enter “reduced propulsion mode” and keeps you from using the generator engine due to being in this mode. This happened as I was driving home from work one day and the car notified me of this issue and entering into this mode. This could leave people stranded if low on battery charge, or in danger due to reduced propulsion. Chevy no longer manufactures this unique egr valve and thus the repair requires obtaining back ordered parts from a manufacturer outside of the us for thousands of dollars. Alternatively you can drive without the egr power cord connected, which means greater emissions and environmental risk/damage. This is not covered under warranty. This is a known faulty part that many Volt owners complain about, which makes it a good candidate for recall. Thank you for your time, shaemus k.

The car has a check engine light and "reduced propulsion" warning. Based on obdii errors, the egr on my chevy Volt failed. I am not in a carb state (I'm in hawaii, though I bought my Volt in CA, which is a carb state). The egr issues plague all gen2 chevy Volts, and tends to break around 40-70k miles into the life of the car. Egr spare part availability is very limited. Given the frequency with which this car breaks for this issue, and the negative impact on emissions, this should be a recall issue nationwide, not just for states that keep carb requirements.

The egr valve failed. This caused the vehicle to have insufficient propulsion while driving. The dealer has confirmed the egr valve is the problem. The vehicle is at the dealership. The check engine light came on. The dealer is now stating the replacement egr valve is a $4000 part because gm stopped making the part when they discontinued the Volt. An egr valve should cost $250-$400 not $4000. The current trade-in value of my vehicle is only $7000. I cannot get my vehicle fixed due to the cost and the vehicle is too dangerous to drive due to the power loss issues.

Several years ago, when I was driving the vehicle, I got a sudden "reduced propulsion alert" and the onboard coolant temperature gauge showed a significant spike in temperature. To avoid overheating, I had to pull over on the side of the highway. In the onboard fuse box, there was a blown f3 fuse. I replaced the fuse and the same issue happened again last year. After some online research, it is clear that the egr valve failed. Unplugging the valve and replacing the fuse has returned the vehicle to normal operations, but it's now out of compliance with local emissions regulations. Gm has failed to properly produce replacement parts. As of Feb 11, 2026, a local gm dealer in bloomington, in quoted a backorder and unclear wait time on a replacement part and quoted me at $2,000+ just for the part. If not for my quick thinking, this part failure could have overheated my vehicle causing extensive damages. Gm has failed to produce enough replacement parts and given the safety issues associated with a blown fuse and overheating, NHTSA should order a recall on this part and force gm to replace the parts for owners. This is a widespread problem documented among Volt owners, and the only stopgap issue is to drive the vehicle out of compliance with local emissions rules.

This is a safety issue for chevy Volt. After seven years of good operation, our 2017 Chevrolet Volt stopped running in traffic while we were driving on 18 Dec 2024. The check engine light was on, and "reduced propulsion" message on dashboard panel. We brought it to the dealer from whom we purchased the vehicle. Tech report paraphrased, customer states ck engine light is on and "reduced propulsion" message on dash fault codes: p0030, p0031, p0054, p0135, p0403, p0405, p0443, p0458, p0489, p0597, p0598, p06da, p06db found fuse [f03] blown for egr valve likely egr valve sticking and causing fuse to blow. The technician stated the exhaust gas recirculation (egr) valve is defective, and needs to be replaced. Replacements are scarce, on backorder, and can be many weeks or months to wait for a part. Many report their Volt unusable, sitting idle, waiting for egr replacement. Egr valve replacement cost is quoted as $2800, which is quite expensive for a valve replacement. This has been happening in recent time to many Volt owners. There are many reports in online forums and no the gm forum website. . Read more...

Driving on gas on the highway, the adaptive cruise control suddenly disabled with a "reduced propulsion" message on the dash and a check engine light. The car started struggling in its propulsion. We found an autozone and scanned the codes, and multiple were returned. A google search pointed us to the "walk home" fuse, which indeed had been blown. Replacing that fuse and disconnecting/reconnecting the battery eliminated the errors. Less than a week later during highway driving (the next time the battery charge was used up and it switched to the ice) I got another check engine light, but this time without the "reduced propulsion" message. Scanning at autozone again revealed a p0404 message referencing the egr valve. Due to the limited availability of the part I have called into covert bastrop (bastrop, TX) and am waiting to hear back on their ability to fix the car.

The vehicle tells me to "stop and shift to park" while I am driving, and power was lost to accessories such as the climate control. Since the egr was identified as the cause of the problem, the car remains on "propulsion power reduced" mode. The egr has been backordered for months, if not years, and aftermarket third-party egr valves are not readily available either. However, there is no recall, and this is clearly a common problem on these vehicles as attested on gm-volt forums. The egr failed about one year ago, but now the message on reduced propulsion power is presented every time I start the vehicle.

Vehicle went to low power mode on the interstate (i4) and was unable to drive at normal safe speeds. Engine overheated and would not allow vehicle to drive over about 10 mph, had to drive slowly on interstate until I could pull off safely to let it cool and get towed home. Technicians verified it is the known egr valve issue, which happens often and isnt covered under any warranty. From research online this is a common problem that strands people in Volts and gm wont fix and cant even get more parts for to repair vehicle. Can leave people with sudden power loss while driving and limit driving speeds to unsafe levels unexpectedly.

On [xxx], while driving on [xxx] in virginia, the check engine light came on in my chevy Volt. A message on dash said that there was reduced propulsion, and the gas engine quit running. The car switched to battery power, which would not have lasted long enough to get us home. At this point, we were stranded on a very busy highway which seemed quite dangerous. Using battery power, we were able to get off the highway. We then made arrangements to have the car towed, approximately 150 miles to a car dealer/repair business in frederick MD. The vehicle was checked out by the car dealer who identified the egr valve as the problem. However, they did not know when the part would be available , and still, 4 weeks later, do not have any date for availability of the broken part. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Check engine light came on. Moran Chevrolet dealership says the code is related to the egr cooler and egr valve. They want me to pay $3,175. 23 for these two parts - however, they can't guarantee that I will get the parts as they are on backorder, and no idea when they will get parts. This is outrageous. I asked, "what if the part doesn't come in?" the dealer's response, "then we will refund your money, but, we will keep $250 for inspecting the car. " "and what if I don't fix it?" their response: "eventually, your car will stop working. " "what if the car is on the freeway and just stops?" their response is unsettling for me and hopefully every driver on the road: "we haven't seen that type of failure, yet. ".

While driving, a warning chime sounded and a message appeared saying "propulsion power reduced. " the check engine light also appeared. The car lost power, would accelerate only very slowly, and eventually died along a busy road. After a period, I was able to restart car and drive very slowly to dealer. I was told that the problem was a faulty egr valve, which was blowing a fuse and would do so again. Dealer was unable to find a replacement valve anywhere in the nation. Gm apparently is not manufacturing replacements for this components, and from reports found onliine, plenty of others have had the same problem. The temporary fix is to disconnect the egr valve, which results in increased vehicle emissions. I will be unable to pass my next emissions test next year. The safety issue is that the vehicle can quit running without warning in any situation.

Experienced severe engine failure while driving on the freeway, which cost to be in operable due to failure of egr valve. This is a warranty repair however gm has part on backorder for over a year with no plan to fix. My car is now disabled and I have no other transportation.

Reduced propulsion power and check engine light. Egr valve failure per mechanic. Part has been on a global back order for 1. 5 years. The car will not pass emissions testing and can blow a fuse that will make the car inoperable. The part is also costly at 2400. 00 without labor costs. My car has 83,000 miles, is well-maintained and only 7 years old and now I can’t drive it or sell it.

The contact 2017 Chevrolet Volt. The contact stated that while driving approximately 55 mph, the vehicle switched over from battery to fuel and a message was displayed that there was no fuel available. The exhaust gas recirculation (egr) valve failure light illuminated, and the vehicle started decelerating. The contact pulled over to the side of the road and restarted the vehicle. The contact continued to drive at slower speeds. The vehicle was taken to the dealer where it was diagnosed that the propulsion power was reduced. The contact was informed that the battery energy control module needed to be replaced. The dealer later found upon further inspection that the egr valve needed to be replaced but was not replaced. The contact stated that after having the repair completed the failure occurred approximately 3 times. The vehicle had not been returned to the dealer to be diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 111,722.

On 8/30/2024 I had driven my 2018 Volt (purchased new on 3/27/2019), with about 45,000 miles on it, on a normally 5 hour trip. About 3 hours into my trip on I-94 my car suddenly slowed down with a "reduced propulsion" message and a check engine light that came on. (the engine probably has run less than 25,000 miles of the total miles I have driven it, with the rest being purely on battery. ) I was extremely fortunate to have been in the slow lane when the car suddenly stopped accelerating. This could have easily turned out very, very bad. The next day I had a dealer diagnose the car for a little over $400 - they told me there was a problem with my engines egr valve and that the parts were back ordered so they couldn't give me an indication of when it could be repaired. I got the car back to my home dealer and they charged me another $200 to re-diagnose the problem and came the same conclusion of a bad egr valve. They too have been unable to get a valve from gm. They have quoted me about $4,000 to have a new valve installed when they can get one. Heck, the car only has 45,000 miles on it!!.

The contact owns a 2018 Chevrolet Volt. The contact stated that while driving at an undisclosed speed, the vehicle lost automotive power. The check engine warning light illuminated. Shortly afterward, the message "reduce propulsion, engine will not start" was displayed on the instrument panel. The vehicle was towed to a local dealer where it was diagnosed with a defective egr valve. The contact was informed that the egr valve needed to be replaced. The vehicle was not repaired due to the cost and lack of parts availability. The vehicle was towed to the residence. The contact believed that the cause of the failure was related to high temperatures. The manufacturer was made aware of the failure. The failure mileage was approximately 69,000.

The contact owns a 2017 Chevrolet Volt. The contact stated while driving at an undisclosed speed, the vehicle stalled with the message “gasoline engine not available” displayed. The vehicle was restarted; however, the failure recurred. The vehicle was taken to an independent mechanic where it was diagnosed and determined that the egr valve had failed and needed to be replaced. The vehicle was not repaired. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 80,000.

I was driving on a highway around 70 mph on cruise control, without warning a “propulsion power reduced” message came up with the check engine light turning on and the car stopped accelerating/let off of cruise control. Very dangerous when driving at speeds above 70mph. I took the car to chevy and they said it’s a egr valve issue and that it would cost roughly $3,800 and the part is on massive back order. R reading online, there’s many Volt drivers with the same issue and can’t get the part for months on (with some being offered a repurchase of the car from gm so the problem would go away) it seems like chevy and or gm do not have sufficient parts to fix the massive amount of Volts having this specific problem and on top of that, this is the largest quote I’ve seen for this repair.