Other Fuel System Problems of Chevrolet Volt - part 2

Component/system failed: the engine of my 2016 Chevrolet Volt experienced a sudden internal crack, leading to complete engine failure. The engine is available for inspection upon request. Safety risk: the engine failure rendered the vehicle completely inoperable, posing potential risk if it had occurred while driving. Sudden loss of engine power could have caused a crash or left me stranded in traffic, endangering myself and others. Problem reproduction / confirmation: the failure was confirmed by a gm dealership, which performed a full inspection and documented the engine crack. The dealership verified that the crack was sudden and not caused by negligence or improper maintenance. Inspections by others: the vehicle has been inspected by the dealership, and all reports are available. I have also submitted the issue to gm corporate for warranty review. No police or insurance representatives have reviewed this, as this was a mechanical failure with no collision. Warning lamps or symptoms: no warning lights, messages, or unusual symptoms appeared prior to the failure. The engine appeared to operate normally until the sudden failure. Upon failure, low oil and low propulsion error message appeared on dash. Current no dash lights are on in the vehicle. Assessment of cause: based on dealership inspection and documentation, the failure appears sudden and possibly related to a defect in emissions-related engine components. No external damage or user error contributed to the failure.

See all problems of the 2016 Chevrolet Volt 🔎.

Component: battery energy control module, available from dealership atm daughter's safety compromised when vehicle power decreased quickly to 5mph in the middle of fast heavy city traffic. The problem has been confirmed by Chevrolet dealership service department the vehicle has not been inspected by other than dealership service center. I contacted gm, and was told that the component was replaced once already in 2021, so they will not replace it a second time on special coverage n232432680 released March 6, 2024. Warnings:propulsion 11/3/25 power reduced and check engine light on 11/3/25. Gm dealer service center cleared codes, did a software update 11/7/ propulsion power reduced and check engine light again. Vehicle is at gm dealer service center.

See all problems of the 2018 Chevrolet Volt 🔎.

P0401, p0b9a loss propulsion power on highway shift to park issues and car uses gas before electricity is empty.

On 10/14, I was driving the car to my job, when the car suddenly switched from its electric battery power to its internal combustion engine. The vehicle's information screen only showed that the battery was unavailable. I was able to operate the car on only the internal combustion engine to arrive at work. However, when I went to leave several hours later, the car would not start. The car was towed to a dealership and apparently repaired after about a week. However, the repair, a software reset, did not fixt the underlying issues, and on 10/27, after having the car for five days, the car again failed on my way to work, displaying a "shift to park" message and not starting. I towed the car to the same dealership, and they had it until 11/04. I recovered my car and drove it again to work that same day, but the car failed again due to the dealership not correctly diagnosing the issue, which appears to be the becm, a failure related to bulletin n232432680. Due to this issue, I was left stranded on a busy highway for several hours on multiple occasions, and have not have a working vehicle since 10/14, meaning I have had to call off of work on multiple days, losing non-trivial amounts of income and undue economic hardship, due to this issue. Neither the dealership nor general motors have offered any kind of help or support, and have generally attempted to avoid responding to my repeated phonecalls. Prior to this issue, there were no warnings or symptoms that I observed.

See all problems of the 2017 Chevrolet Volt 🔎.

Chevy had done an update for the propulsion power being reduced. In 2024, I had to do another update when the check engine light came on. After that the electric battery power decreased, I am only getting 17 miles per charge. August 2025, the check engine light came on again. I had it check and no codes came up. While driving home on the freeway, the propulsion power being reduced warning came up. I had to pull off the freeway. Once I turned my vehicle off, I was unable to drive my car. There was not any acceleration. I had to have my car towed 50 miles home. A mechanic was able to repair it at that time. On 10/7/2025 the check engine light came on again and once again no codes appeared, on 10/14/25 the propulsion power being reduced warning came on again. I was able to get home safely, but I got off the freeway and took side streets home. At this time, the vehicle will not accelerate.

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.

Vehicle propulsion system failed. According to chevy dealer the battery energy control module and a/t control park switch and harness failed. Warning lights came on when the failure happened. Failure happened just past the extended 150k mile warranty. But car in only 8 years old.

The car can't decide if it wants to use the battery or the engine. It shows zero charge even though it is full. It lurches at stop lights as it tries to decide whether to use battery or engine. It says "propulsion power reduced". "not able to charge". "shift to park". Check engine light is on.

My 2015 chevy Volt has been experiencing ongoing mechanical and electrical issues, including random power loss, reduced propulsion warnings, and sudden vehicle shutdowns with no prior indication. These problems pose a serious safety concern, as the car can lose power unexpectedly while driving. Despite these issues, gm has refused to service the vehicle or unlock necessary components because they no longer manufacture or support the required parts. As a result, I am left with an unsafe and unreliable vehicle with no available remedy from the manufacturer. This is forcing me to trade in the vehicle at a loss.

See all problems of the 2015 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.

Fuel leaking from fuel tank at filler inlet. Defect in fuel tank assembly. Large puddle of gasoline formed under car after refueling causing buildup of fumes in closed garage. Vehicle has not been inspected by anyone other than owner. There were no warning lamps prior to failure.

See all problems of the 2013 Chevrolet Volt 🔎.

Propulsion power reduced error has happened many times but the recall lookup shows that there are no active recalls on our car. There was a recall on this problem in 2018 so I think it may have been done my the last owner but it is still having this problem.

In 2020, gm issued a recall (#n192273600) for emissions pipes on the chevy Volt that could be compromised by rubbing against the a/c hose connector. I took my vehicle to my local dealership (chesrown Chevrolet) to have this issue remedied, that same year. This year, my check engine light came on and this same dealership informed me that the cause was this same issue (I. E. A compromised emissions pipe due to rubbing against the a/c/ hose connector). Assuming the fix was conducted per gm's specs, gm did not provide an adequate fix for their faulty design.

Check engine light came on car was able to start but the cluster started reading the battery being full with a charge. And was having trouble starting. Fast forward a day I get a propulsion system reduced warning on the dash as I’m entering the highway and the car fails to stay on I’m able to pull it to the shoulder and I cannot get the car to start. Get towed home throw it on the charger and the dash says unable to charge. Swap the 12v (checked it and it died) thinking that might fix the problem since the car was able to power on but not start. To no avail through my code reader and code p1e00 code. Took it to my local dealer and was told id need replace the becm… and was quoted 33xx for the repair. Had any of this happened while I was on the freeway I might not have been able to make it to the shoulder potentially putting myself and others on the road and a possibly fatal situation.

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).

Propulsion power reduced and check engine light came on my 2017 chevy Volt - been happening a few times now the last week.

While driving 50mph on a 4 lane highway, propulsion reduced speed and engine unavailable message came on and the car immediately shut down, a car almost hit me because of it. I had to hurry up jump out and try and push it off the road out of oncoming traffic! after about 15 minutes of turning car off and then back on. It finally started again, I then drove 1/4 mile and it did it again this time as turning left across a 2 lane highway with traffic oncoming, once again had to hurry up and jump out and push it out of the road! this was such an extremely scary situation for me and I thank god my wife wasn’t driving with our daughter and grand kids! this is the 2nd time because on 8/1/2025 it did the same thing while driving on a major 4 lane toll road, was able to pull off to side of the highway but had to be towed home!.

See all problems of the 2014 Chevrolet Volt 🔎.

While driving approximately 65 mph on an interstate highway, the vehicle's check engine light illuminated. Very shortly after, the dashboard screen displayed the message "propulsion power reduced," and the internal combustion engine turned on. The vehicle's power was significantly reduced, almost causing an accident when another car started merging without checking their blind spot, forcing me into the left lane in front of a third vehicle that had to brake sharply to allow me to accelerate to keep up with traffic in that lane. Upon scanning the vehicle with an obdii reader, codes p1e00, p1f06, u2603, u2604, u2605, u2606, u2617, and u2618 were present. Together, these codes indicate an issue with the battery energy control module (becm). The vehicle is currently at a Chevrolet dealer, awaiting replacement of the becm under the applicable warranty extension.

On [xxx], our 2018 chevy Volt experienced a critical becm (battery energy control module) failure while being driven by our [xxx] daughter. The failure caused the vehicle to enter limp mode, resulting in a severe loss of power and the inability to shift properly. Most alarmingly, the brakes failed to function correctly—despite being fully engaged, the car continued to move forward at a red light, placing our daughter in immediate danger. She was only able to safely stop the vehicle by maneuvering it off the road into a parking lot. This becm defect is a well-documented issue for chevy Volts from 2016 to 2018. However, Chevrolet has refused to cover our VIN under the existing special service bulletin, despite our vehicle using the same faulty part number as those included in the recall, and has provided no explanation for this exclusion. As a result, we are being forced to pay $2,100 out of pocket to replace a part that gm knows is defective. This is an unacceptable financial burden for a safety-critical issue. Gm should immediately issue a recall for all vehicles equipped with this faulty part number to ensure the safety of all drivers and prevent further undue costs. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Driving at 75 mph on the freeway the power completely cuts off an a message appears on my dash "propulsion power is reduced" - pressing the gas barely gives any power, imagine being in the middle of flowing traffic doing 75 mph to close to 20 mph. Research shows me this is a known issue with gm and the problem is with the becm control module. There is also the issue of the egr valve which apparently is tied into the becm. I brought to the chevy dealer and they said the becm needs to be replace ASAP because gm knows this is a dangerous situation and gm extended the warranty on this part to 150,000 miles. My vehicle is at 152,400 miles and they will not cover this. This is a serious issue that should be a recall that forces gm and chevy to pay for this fix as it is something they have been aware of for years and it is a major accident waiting to happen. Please make them issue a recall for the becm fix.

Portion message car stalled on hey.

On June 27, 2025, while driving, the vehicle displayed a "propulsion power reduced" warning message and a check engine light illuminated. I immediately experienced a loss of power. I brought the vehicle to an authorized Chevrolet dealer the same day. On July 1, 2025, the dealer diagnosed the failure as a faulty battery energy control module (becm) and high-voltage system fault (code p1e00), requiring a full replacement of the high-voltage battery pack (part #24296900). The manufacturer (gm) was contacted, and the replacement battery was ordered on July 2, 2025. As of December 2025, the vehicle remains in dealer possession (over 5 months) with no repair completed. The manufacturer has stated the part is on indefinite backorder with no eta. The failure of this component renders the vehicle inoperable and presents a safety risk due to sudden loss of propulsion power while in motion. The manufacturer has confirmed the failure but is unable to provide a remedy within a reasonable timeframe.

Vehicle displayed reduced propulsion and shift to park while driving on highway then suddenly stopped. Dealer said battery failed after a year of diagnosing issue. Issue may be becm which has extended warranty service but dealer not addressing the issue of car stalling but instead other costly minor issues leaving the vehicle a safety concern. Replacing battery with a bad becm would lead to exact same issue.

Driving on interstate doing 65 and suddenly warning pops up and car dies immediately. I was lucky to get over to the edge and not wreck or cause an accident. Found that the 12 Volt battery was not being charged without warning until failure. Found a 15 amp fuse blown in the high Voltage relay module.

I got a warning from my car a little over a week ago (around 6/1, unsure of exact date) that I needed to service the battery charging system, but then the check engine indicator light shut off and so did the warning light. The hybrid battery took a charge with no issues after that. Then, I left work the evening of 6/9 and drove home. On my way home, the check engine light came back on, followed by warnings that I needed to shift to park. Before I could pull over, my car stopped moving. Cars had to stop abruptly behind me and navigate around me into incoming traffic. I shifted to park, then tried to turn my car off and on again. I tried to switch between the gas engine and the battery, I tried to move my vehicle in any way. I couldn't get it into neutral to push it out of traffic. I turned on my hazard lights and a person came out from his house to assist in directing traffic away from my car for about an hour while I waited for a tow truck to arrive. The kind bystander who directed traffic and I were very concerned about a car accident happening due to my stopped vehicle. A police officer stopped by to check on us and try and get my vehicle into neutral but he was unable and said he was on his way to a 911 dispatch so he did not write a report of any kind that I could see. He told me the vehicle placement was not safe and I agreed with him. The tow truck came as he was leaving. The dealership I sent my car to said it is likely a short circuit in the 12v battery but I know the becm in the chevy Volt is known to cause similar behavior. Dealership refused to service the becm when asked about it.

On may 26, the car was running in electric mode and switched to gas because the power batteries were depleted. Shortly after switching to gas mode, lights came on the dash board saying engine not available get service immediately. I was on a highway at the time and fortunately had just enough left to get off and the car would not move any further. Turning the car on and off did not resolve the problem. It had to be towed to a chevy dealer. Even after an hour, the messages would come on when trying to start the car. The next day, the dealer called and said they could find no problems with the car and it works fine. This happened once before, but that time there was enough charge in the battery to get home and then later it would start without the message.

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.

Becm module is failing producing a reduced propulsion message. This is happening while driving which is a safety issue. Limiting the ability to drive, handle and brake with the vehicle.

While driving the car displayed “reduced propulsion power” on the dash and then I lost all drive power and could not switch the plug in hybrid from electric to gas engine mode. The vehicle had to be towed to the dealer who stated that the battery electronics control module and perhaps the battery needed to be replaced. The check engine light came on slightly before the incident.

There was a recall for the hpcm2 where the propulsion power reduced warning would come on whenever the car's cell battery was depleted. This happened with my car and there were several times it slowed on the freeway and on exit ramps as I tried to safely get my car off the road. It first happened on 4/13/25. I took my car to a regular mechanic who charged me 3k of repairs on basic maintenance, new tires, etc but were unable to fix this issue. They advised it was a manufacturer issue and to go to a hybrid specialist or a dealership. I called a hybrid specialist who found the faulty code and advised the same. I took my car to felix Chevrolet (3330 s. Figueroa st. La, CA 90007) and they offered to do many maintenance service items that I had done earlier this week in an attempt to fix the hpcm2 software bug. After I told them that the maintenance items were complete, they called me back an hour later to tell me I needed other maintenance repairs that are less common. When I gave them the description of the recall and re-explained this is identical to my car's symptoms and that this manufacturing issue may have affected other vehicles like mine that were outside of the recall batch, they told me it was impossible to apply this diagnosis as long as my VIN number was outside of the recall batch. Can you please add my VIN to this recall or have my car reviewed by someone who can debug the software?.

Unknown my car has been accelerating and decelerating on it’s own while I’m driving. I got it checked with fix finder and states that my egr valve and abs system failed. I brought it to a mechanic for a repair and I was told that the valve was unplugged so they plugged it back in and cleaned it , and said that everything was fine it said it might also be the cause of the failed abs system but everything looks fine. After I got it fixed, it’s doing the same again and it’s worse this time. The car is accelerating on it’s own faster than what it did but the dashboard is saying 0mph. I was driving in the highway when it happened and it’s scary so I had to pull over.

Vehicle lost all motive power while driving on the highway. Vehicle is part of gm special coverage program number n232432680 for becm issues up to 150,000 miles. Vehicale currently has 109350 miles. Failure on highway while driving is unacceptable and should have been a recall instead of special warranty. Gm support is not helpful with service or transportation (one month out for service only at select locations). Vehicle will not restart and had to be pushed from the roadway.

Battery energy control module failure there is an existing nthsb issue related: n232432680 I was told my VIN is not included in this issue, so the failure is not covered under warranty by gm. That said, the same failure and symptoms occurred (prompt multiple battery cell failures leading to electric drive inoperable). I was told, by others with Volt's who had same issue, that my VIN was not included because it was under a pzev warranty since it was originally sold in California. I do not live in California, so the extended 150k mile / 15 year warranty does not apply to me. Car is currently at the dealership, and I was told the same repairs as in this nthsb issue are needed at a price of > $2,500. As such, I am asking to have my VIN added to this issue for reimbursement.

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).