Gas Recirculation Valve (egr Valve) Problems of Chevrolet Volt - part 2

Received the vehicle on 8/6/24 with 96,500 miles on it. On 8/15/25 I received a check engine light with error code p0401 indicating an issue with the egr valve. I took the vehicle to my dealership which confirmed the issue and was informed that it was a common failure with this type of vehicle. I was placed on a waitlist for the part which as of today, 9/9/24, still is not available. A quick google search shows that that this error is extremely common for these vehicles.

See all problems of the 2017 Chevrolet Volt 🔎.

Egr valve failed while driving on the freeway. Loss power. Check engine light on. Propulsion power reduced. It is safety and emissions related.

Reduced propulsion message appears on the dash and car lost propulsion on the highway. The egr blew a fuse and the car enters the walk home mode. This problem should be covered under warranty but my dealership says it is not covered. This issue causes the car not to be able to drive. Chevy is back ordered for the part and there is no estimate of when the part will be available. They apparently do not make the part anymore and there is no fix. Th egr seems to have bad soldering and blows the fuse #3.

The exhaust gas recirculation (egr) valve failed. Confirmed by dealer, culver city Chevrolet, 8/29/2024. Failed egr valve causes gas engine to emit harmful smog forming emissions. This part is still covered by 10 year, 150,000 mile warranty. However, gm/Chevrolet has not made a replacement available and gm representatives have provided no estimate of when or if that replacement part will be made available.

See all problems of the 2016 Chevrolet Volt 🔎.

Egr valve has failed leaving me stranded on side of the road. Problem was confirmed by a Chevrolet dealership. Engine light came on moments before it happened.

Car displayed a lower power mode on dashboard. Approximately 20 miles later car switched from gas mode to electrical battery mode. Fortunately there was some charge remaining in the battery that I was able to get off freeway and charge car for 3 hours to make the 30 miles home. Dealer thinks problem is a defective egr valve and I am awaiting a part for this repair for 37 days and counting. The low power mode states it is limited to 35 kw of power but I was surprised when the engine cut off to battery mode. If I had used up the battery charge on the first portion of this trip I do not know how suddenly the car would have stopped on freeway.

While driving our 2018 chevy Volt, dashboard warning message “propulsion power reduced” displayed. Vehicle performance was not otherwise affected. Subsequent diagnosis from our chevy dealer was, among other things, a faulty exhaust gas recirculation (egr) valve. We were informed that our vehicle was “no longer safe to drive in this condition” and the vehicle has been sitting on the dealer’s lot awaiting a replacement part for 2 months and counting, with no expectation of near-term resolution of our problem. We are aware that this is a widespread problem on 2017-18 Volt models, with many dissatisfied owners.

See all problems of the 2018 Chevrolet Volt 🔎.

On July 21st, 2024, the exhaust gas recirculation (egr) valve failed. It blows the “non walk home” f03 fuse, resulting in the check engine light and a “propulsion power is reduced” warning message. The vehicle is not to be driven in this condition. The egr valve is included in the emission warranty parts list and the pzev emission control system defect warranty (15yr/150,000mi) is active on the vehicle. The vehicle has been to two Chevrolet service centers, mission bay Chevrolet on July 22nd and kearny mesa Chevrolet on August 6th without successful repair. They explain that the egr valve part is on backorder and have no estimate for its availability. The vehicle has been at the kearny mesa Chevrolet service department for 55 days. Having the vehicle suddenly and unexpectedly enter a diminished propulsion mode at freeway speeds is unsafe.

Purchased the '17 chevy Volt for my daughter on [xxx] with 58,867 miles. On [xxx], 60,600 miles; she was driving on the interstate when the engine temperature spiked, followed by a check engine light and a warning message: "engine unavailable. " the vehicle suddenly lost power when she reduced pressure on the accelerator, causing a rapid reduction in speed. Nearly causing her to lose control. The vehicle's obd codes were scanned at a nearby auto parts store resulting in 30 dtc appearing. I found hundreds of complaints and posts about the f3ua fuse blown and a faulty egr valve. A service bulletin for this issue was published by gm in Feb 2023. I notified the dealership of the issues and the vehicle was brought to deacon jones chevy of clinton, nc on July 16th. The service department informed me that the 12v battery was bad and needed replacement to "correct" the issue, at a cost nearly $550. I asked if the fuse mentioned was blown and was informed that it was not. The check engine light was cleared and my daughter drove home. Before getting home, the check engine light came back on, the temperature spiked, and "propulsion power is reduced. " message appeared. This was accompanied again by a rapid reduction in speed nearly causing a collision. I called the dealership back and informed them of the incident. They requested to have the vehicle brought back to the shop, however, towing was out of the question because the dealership is 70 miles from me & I did not want to drive the car in its condition. I took the vehicle to team chevy in swansboro, nc, who ran proper diagnostics. I was informed the f3ua fuse was blown, caused by a short in the egr valve. The original dealer offered to split the cost, but team chevy said they could get the part & match price. When ordered, it showed the egr valve was backorder with no eta. 6 weeks in and no safe transportation for my daughter and grandson. Significant safety issue with no replacement parts or accountability, ludicrous. Information redacted pursuant to the freedom of infor.

July 3, 2024, while driving on pennsylvania turnpike, check engine light came on with reduced propulsion warning. Continued driving to destination without incidence. Did not drive again until July 5th. July 5th while driving using "hold" method of propulsion using internal combustion engine, check engine light remained on, after the engine warmed up, all of the sudden, there was a noticeable reduction of power, followed shortly by the internal combustion engine shutting off while I was entering onto an interstate highway ramp. Fortunately I was able to pull off to the side of the road and back down the ramp without incidence and return home under grossly reduced battery propulsion. July 8, took vehicle to Chevrolet dealership (baierl Chevrolet, wexford PA) under battery power. Was told ecm module was bad. Ecm module was replaced, error codes cleared, vehicle ran as expected. After driving approximately 50 miles, check engine light with reduced propulsion warning returned. Turned vehicle around and returned to the same dealership. Was told egr valve was bad while blowing fuse f03 (non walk home circuit). The dealership did not have a replacement in stock and it would take 7-10 days to obtain a replacement. I had to rent a vehicle out of my own pocket to return home for employment purposes. July 11th, I emailed dealership's service advisor for status of replacement part. Never heard back from service advisor. July 15, 11:24 am, talked to dealership service advisor, was told part was in transit with no estimated delivery date. July 22 called service adviser and left a voice mail message for a return status call. Never received a return call. July 23, called dealership, talked to parts department for part status, was told part had not shipped from warehouse yet and there was no estimate on shipment. After having to return the rental vehicle, I am without a vehicle for my daily required activities. Not an acceptable situations.

The egr valve in the 2016 chevy Volt will fail blowing fuse 3 which will also take out the engine oil pressure control solenoid, the evap emission purge solenoid valve, the engine coolant thermostat heater, and the oxygen sensor 1 as they all share the same fuse. The car will tell you that the engine is unavailable and, if you are out of hybrid battery power, will leave you unable to move the vehicle. In my particular situation it left me stranded blocking one lane on a two lane s-bend road on a 5-9% grade mountainside with no cellphone reception. Thankfully the car stopped far enough away from the previous bend that people had time to see me and I didn't get rear-ended. If I had stopped 20 feet sooner that likely would not have been the case. The replacement part for the egr valve is impossible to find as it is back ordered everywhere and places that will let you back order it will try to charge $1927 just for the part (no installation service included). If you live in a state without emission checks then you can unplug the egr valve and replace the fuse but that means your producing more pollutants. Until gm gets their act together and offers affordable replacement parts I don't see another alternative.

Driving at highway speeds, check engine light came on with a warning of "reduced propulsion power" and sudden loss of speed in heavy traffic. Dealer diagnosed issue as failed egr valve but is unable to source repair part due to frequency of failure causing years-long backorder.

Egr valve clogged and failed on a long trip, bricked the car and had to tow many miles back to home shop. Now have been waiting 9 months and still no idea when the part will be available from Chevrolet. My shop and I have claims to Chevrolet for the part for service but still nothing and is getting so we are inconvenienced in travel.

The egr (exhaust gas recirculation) valve has failed, which causes issues with the fuel propulsion system, can cause the cooling system to fail, and affects the emissions system. We are unable to obtain a replacement valve anywhere and have been on a waiting list at the dealership for months. The car is not safe to drive in this condition.

While driving down the highway a "reduced propulsion" message appeared on the dashboard and the drive became very rough if speed changed, also the engine temperature increased but it did not overheat before we could stop. This was diagnosed as an exhaust gas recirculation (egr) valve failure. I spoke to multiple dealers and did research online as well and this is a very common issue on this vehicle. So common that the part is impossible to get and has an eight month wait which means I cannot drive my vehicle. What component or system failed or malfunctioned, and is it available for inspection upon request? egr valve how was your safety or the safety of others put at risk? my car had reduced propulsion, engine temperature increased and it suddenly lost speed quickly on highway when my foot was removed from gas pedal. Has the problem been reproduced or confirmed by a dealer or independent service center? yes. Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? no, Chevrolet is aware of this issue and say we just have to wait 8 months for the part. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? no pre-warning a "reduced propulsion" message and a check engine light turned on at the time of the egr valve failure.

While driving on high-speed devided highways including stretches where traffic was 2-way (single lanes separated by concrete barrier during road maintenance) chevy Volt indicated "reduced propulsion", and in 2 cases forced shut-down of electric and gas engine where the single-lane travel had cement barriers on both sides of the driving lane. In at least one case, the engine forced 30-40 mph travel until a break in the right-hand cement barrier was interrupted and I could get off the highway. In another case, the engine and fuel propulsion shut down but there was a breakdown lane on the right allowing traffic flow but exposing me to risk due to how close 65 mph traffic was passiing me. In each failure case, after turning off and re-starting the vehicle, the vehicle seemed to have re-set propulsion control and I could continue the trip at normal speed until another warning but not complete faillure occurred (both lanes being available so I could drive to an exit, turn off the ignition, restart and resume the travel). I believe the failure was in the becm (battery energy control module) but the Chevrolet dealer identified an egr failure that prevents their repair team from diagnosing the becm. Whatever the failure was, it put me iin a very dangerous situation in at least 2 points in my 600 mile trip.

On a recent trip on a highway on our 2017 chevy Volt, the exhaust gas recirculation [egr] failed and caused "low propulsion" errors. We ended up with a surprise bill of more than a thousand dollars to replace the egr cooler assembly, but the problem was not resolved. The dealership then said we need to replace the egr valve which is estimated above $2700 plus labor. Upon checking the gm-volt users community this is a reoccurring issue on several thousands of vehicles and the inflated price is due to the fact that gm redesigned the egr valve to fix their original faulty design. We as consumers shouldn't be responsible for such an outrageous cost and mainly safety due to a design flow by gm. This issue should warrant a recall by gm to fix the issue once and for all.

Failed egr valve. While I was driving, I got a "propulsion power reduced" message and "engine unavailable. " my car slowly began losing power, leaving me with about 30 seconds to safely pull over. I had it towed to the dealer and they diagnosed a faulty egr valve. This seems to be a widespread problem with the Chevrolet Volts. To make matters worse, the replacement part is extremely hard to find, with many people waiting on backorder for over a year.

While driving on the highway, the egr valve in my car malfunctioned, initially causing my dashboard to read "propulsion power is reduced". After continuing to drive the car, the dashboard read 'engine not available, service soon', where it stalled and we had to restart the car. After restarting, the car went into ev mode with significantly reduced speed. Our safety was put at risk due to the initial stalling and subsequent reduced speed on the highway. The problem has been reproduced since the initial incident and our dealership confirmed the problem relating to the egr valve which continues to blow fuses when the engine is over-exerted while using gas. The dealership said that this is covered under warranty however, there has been a 5-year back-order on the part and they are refusing to offer any loaner car or compensation for a rental car.

The exhaust gas recirculation (egr) value has failed after only 20,000 miles of engine usage in my hybrid car. This is a highly-common part that fails and when it fails it shuts the engine down while driving; which leaves the driver stranded. General motors does not have the part available to purchase and has been on backorder for nearly 4 years. They do not have a resolution and they are not recognizing the gm service bulletin that was released 21-na-116 in feburary 2023. This is unacceptable. The dealership wants thousands of dollars for a $150 part (that you can't purchase).

My 2016 chevy Volt experienced a loss of propulsion power multiple times due to the egr (exhaust gas recirculation) valve failing. The malfunctioning egr valve caused the f3 fuse to break, disabling the cooling system and forcing me to pull over immediately, which posed a safety risk, especially in high-traffic areas or on highways. The problem was reproduced when the replacement egr valve also failed. It is not specified if the vehicle or components have been inspected by the manufacturer, police, insurance representatives, or others. Both the original and replacement egr valves should be available for inspection upon request.

As I understand it, the egr valve failed causing the car to shut down suddenly on the highway. Apparently by blowing the "walk home" fuse. The egr valve has been unavailable from gm worldwide since oct 2023 and there is no estimate when it will, if ever, be available.

The contact owns a 2018 Chevrolet. The contact stated that on several occasions while driving at various speeds, the vehicle lost motive power with the check engine warning light illuminated. The vehicle was steered to the side of the road and restarted each time, but the failure persisted. The vehicle was taken to the dealer where it was diagnosed that the egr valve needed to be replaced and 40 unknown dtc codes had been retrieved. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 55,000.

While driving my 2017 chevy Volt on the highway, a “propulsion power is reduced” message appeared accompanied by the cel. Prior to this there had been no indication that anything was wrong. The warning was quite vague and it wasn’t at all clear what it actually meant so I continued driving. Shortly after this, I began to notice a bit of a “chuggle” or lurching sensation (particularly on hills). This made the acceleration slightly unpredictable, and at one point even triggered the forward collision warning when the car accelerated a bit after I took my foot off the gas pedal (coming up behind another car at a traffic light). I pulled over and attempted to figure out what the issue was. I had a notice regarding the becm recall in my glove box which listed a reduced power mode as a potential symptom, so I scheduled a service appointment (figuring it was that) and continued my trip. I stopped to get gas, then a mile or two down the road the engine overheated and shut off. By sheer luck I had a few miles of range left in electric mode which allowed me to pull over safely, but I was now stranded over 100 miles from home. I managed to get the vehicle to a dealership in danvers, MA where they diagnosed the problem as a failed egr valve. My understanding is this is related to a defect in the valve electronics. The valve failed and blew the f3 fuse, which also supplies power to the engine cooling system. It doesn’t take long for the engine to overheat and it seems this can lead to a complete loss of power while driving when the electric range is already depleted. The valve is currently unplugged while I await a replacement but there is no word on how long that might be. Other Volt owners have had to wait months or even years to get a new valve. The repair quote I received is also unreasonably expensive (> $4,000). I failed my state emissions inspection and am in the process of applying for a waiver. Given how common this is, I'm surprised this isn't already a recall.

My car's check engine light went on and after a while started blinking. The car would not go. When I got it towed and checked by the dealership, they said my egr valve had an issue and needed to be replaced. They said the part was on backorder and it could take months and tried to charge me $2,000 up front to "reserve the part. " it seems like gm has deprioritized this part and is putting drivers like myself at risk of not being able to use our cars and not being able to pass emissions inspections required in my state. This was originally diagnosed in spring 2024 and I have been unable to get a replacement as of January 2025.

My service engine light came on. After that happened, my engine started to get hot. It got up to 230degf, received a reduced propulsion message and wanted to shut down when going 70mph on the interstate (depended on the construction). Quick reaction on my side before the engine shut down I had "held" the battery (which I do for long trips to ensure options in event of emergencies). Meaning I still had energy in the battery that could be used to propel the vehicle. I was able to shut down the engine by unholding the battery before losing control of the vehicle due to no propulsion. The electric propulsion took over and I could get off the freeway. Conditions were: I was driving in a rain storm on a very busy interstate around eau claire wisconsin right around 5-6pm with lots of road construction. If I would have lost the engine and power, I would have crashed at a high rate of speed. I would have lost steering, windshield wipers and headlights. Investigation showed that fuse f03 (walk home fuse) was blown. Further investigation showed that the egr valve circuitry was causing this failure. After unplugging egr valve and replacing the fuse, engine was able to run and not overheat. Plug the egr valve back in and the fuse blows again this is a well known issue on these vehicles and has been around since 2019-2020. Lots of data and information available on this issue on the internet. To make the issue worse. No parts are available for replacing this faulty valve at the moment. Only 6 valves available in the whole USA with those promised to other customers (I called the dealers). Additionally there are more vehicles waiting for these valves. . Vehicle goes to the shop on 4/29 for confirmation of issue and get on a waiting list for the egr valve. I can't believe this is allowed to continue with gm. This needs to be fixed!!!!.

Component or system malfunction: the exhaust gas recirculation (egr) valve in my chevy Volt failed, causing a complete loss of vehicle power and potentially leading to engine overheating. This malfunction has been widely reported among other chevy Volt owners, and the egr valve has been improperly designed. The part is not available for replacement, making it impossible to fix the issue, even though chevy lists the cost at $3,000 to $4,000. See [xxx] as a sampling of people experiencing the problem. Safety risks: the failure of the egr valve puts both my safety and the safety of others at serious risk, as the sudden loss of power could result in accidents, especially when driving at higher speeds or in heavy traffic. Additionally, the potential for engine overheating increases the risk of further damage or even fire. Problem confirmation: this problem has been reproduced and confirmed by my local dealer, who informed me that replacement parts have been back-ordered since April, with no estimated delivery date available. Many other customers are experiencing the same issue and have also been unable to obtain the necessary parts. Inspections: the vehicle has been inspected by the dealership, but no solution has been provided due to the lack of available replacement parts from the manufacturer. The manufacturer has not offered a viable timeline or alternative resolution. Warning signs: prior to the failure, I experienced warning lights related to engine performance. These warning messages first appeared in April, signaling an issue with the egr valve. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

The egr valve failed and has been on order for over 6 months. I unplugged it to keep the car operational, but it will not pass an environmental inspection without a new valve. This is a very common complaint on online forums. Something needs to happen to force gm to resolve this issue.

Egr valve fails causing vehicle to become disabled in traffic or stranded on a remote section of the highway. Also fails emissions testing. Chevrolet has no replacement parts available.

The contact owns a 2017 Chevrolet Volt. The contact stated that while driving at 70 mph, the vehicle stalled. The check engine warning light illuminated as well as the reduced propulsion power warning message displayed. The vehicle was then taken to a dealer where it was diagnosed with having a blown fuse number 3, the fuse was replaced. The contact stated later while driving at an unknown speed, the check engine warning light illuminated. The vehicle was then taken to the dealer victor Chevrolet (7200 pittsford victor rd, victor, NY 14564) where it was informed that the egr valve needed to be replaced. The contact was informed that there was a 50/50 chance that the fuse would malfunction again if the egr valve was not replaced. The vehicle was not repaired due to the egr valve on back order. The manufacturer was made aware of the failure. The failure mileage was 59,352.

Check engine light came on codes indicate the egr and egr cooling components have failed and a propulsion power is reduced message is displayed. Max speed at this point in 10 mph. This would be my second time replacing the egr valve if the parts were available but they are not and there is no anticipated delivery date. The parts are covered in carb states (those that have adopted California's emission rules) but not my state of nc.

Had to replace egr valve after losing power on the highway back in 2022. Lost power steering and reduced engine power while driving at highway speeds, luckily was able to get off the highway and limp the car back to my house. I almost crashed due to loosing engine power and power steering. It's appears to be a becm issue.

Problems with egr valves still in defects, and engine gaz motor loose power. Gm don’t have enough parts to resolve them.

We bought the car for our son when he began to drive. We liked the idea that it was gas and electric. At the time, our son was into electric vehicles. At 44, 000 miles, 7/10/20 the car was taken to the dealership. The engine light was on at this point, the message displayed "propulsion power is reduced". Once the diagnostic was done it was said that the egr valve needed replacing. Of course, this is during the of covid. Everything was shut down. No one is working. It is now a wait game. Prior to this our chevy Volt has been in and out of the dealership with either recall or something else. We enjoy the car because of how it operates with gas and electric. Fast forward it is 80,000 miles now, and the car is at the dealership again. It has currently been there for almost a month. After blowing fuses it has be diagnosed as the egr valve needs replacing again. The part is not available currently. No one seems to know when it might be available. The part cannot be purchased from our local distributor. Gm is the only ones who makes it is our understanding. There is no other dealership near us that has certified technicians who can work on them. We called around and asked. We want to know what the solution is. How can this be prevented? we were over an hour away from home and no dealership was open when it went out the last time. It became worse to the point that we were stopped on the road with flashers on because it was not safe to pullover. Prayer works.

The contact owns a 2017 Chevrolet Volt. The contact stated while driving at various speeds, the vehicle lost motive power and stalled. The contact stated that the vehicle was restarted but stalled again after driving for several miles. The check engine warning light was illuminated. The vehicle was taken to the local dealer, where it was diagnosed that the egr belt needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 90,382.