2018 Chevrolet Volt Engine Problems

While driving on a highway the car started to hesitate, a message appeared on the console "Propulsion power is reduced" and the engine light turn on. After driving some miles, a new message appeared: "Engine unavailable, service soon" and the car only ran on electric power, no motor engine. I had the same problem 3 year ago and the dealer identified the problem as a shorted EGR valve. This time I knew this shorted EGR valve burns the F3 fuse. I managed to get to a car part shop and bough several fuses (15 amp). After replacing the fuse 3 times I managed to get to the dealer. The repairs cost $3000+ (up from $1000+ 3 years ago). This problem is well documented on the GM service technical bulletin "21-NA-116" dated February, 2023. Three years ago I was in the middle of nowhere in South Texas and it took 6 hours to get a tow truck This time I was lucky enough to be close to to a town that the remain battery power was enough to get to the store where I bought the fuses. GM should recall this part and do a proper fix

NHTSA ID

11755062

Incident

Aug 2, 2026

It was the XXX recall for the DTC P0442/check engine light code. The dealership said that the recall had been satisfied in 6/2020 by putting a buffer in to separate the 2 lines but not replacing the part. Now the exact same code DTC P0442/check engine light in the exact spot that occurred for the original recall. The dealership originally quoted $5,093, then after me complaining that it is the same recalled problem they dropped the cots to $2384. I believe that is an agreement that the manufacturer should cover this. Of course I will have to pay to get my car but I would like the manufacturer to reimburse me for it seeing it was a manufacturer default. I spoke to the manufacturer they flat out refused to cover it. I obviously disagree. Would like you to pressure them to change their decision. Thank you, [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11716611

Incident

Feb 2, 2026

The contact owns a 2018 Chevrolet Volt. The contact stated that the battery module became inoperable. While attempting to start the vehicle, the message "Engine Unavailable - Service Soon” was displayed. The contact was unable to use the vehicle. The contact stated that the TPMS warning light was illuminated. The contact associated the failure with Technical Service Bulletin: 18-NA-261. The contact called the local dealer and was referred to the manufacturer for assistance. The vehicle was not diagnosed or repaired. The manufacturer was contacted and confirmed that the VIN was not under recall. The failure mileage was approximately 111,000.

NHTSA ID

11705567

Incident

Dec 15, 2025

Mileage

111,000 mi

My wife and I were on a 200 mile trip and the engine failed about 150 miles into the trip. Was driving and the instrument panel indicated that the engine was in reduced power mode. I switched over to battery power but had only approximately 10 miles of range left so after a couple of miles I switched back to engine power and was almost immediately informed by the instrument panel that the engine was in failure mode. Was fortunate that there was an exit nearby and was able to use the remaining battery power to exit the highway and pack the car before there was no power.the car was towed to a dealer and we were told that the egr valve and cooler had failed.they were replaced and I was told that they were not covered by the federal emissions warranty so the cost would be $4000.the car was driven with the vast majority being electric power.

NHTSA ID

11695779

Incident

Oct 8, 2025

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.

NHTSA ID

11693733

Incident

Oct 9, 2025

The dealer reported having repaired an emissions recall for a fuel vapor leak, however the repair was ineffective and the vehicle still reports the leak as a fault code "slow" and "fast" emissions leak. The dealer refused to recheck their work without payment. Recently I came into possesion of a borescope camera and was able to photograph the dealer's "repair". The photos clearly show the parts for the emissions repair are located in the wrong place as compared with GM's own service bulletin. Therefore the dealer did not do the repair, or failed to do the repair, and refused to check there own work without compensation when informed of the continuing problems and left me to do their recheck of their work at my own expense. I have provided photos of the GM prescribed parts placement and the incorrectly placed parts in my car as well as the resulting damage. We never experienced the relief intended to be provided by the repair service. They claim to have performed the necessary recall service, but THAT IS A FALSE CLAIM. See Chevrolet TSB N192273600. NOT PERFORMED CORRECTLY SO FAILED. The dealer, Haselwood Chevrolet, Bremerton Washington, was contacted by phone and email but offers no response. They have the pictures of the botched repair job. Additionally the car needs warranty service for a bad park switch which service they refuse to perform without my agreeing in advance to pay for that in warranty repair.

NHTSA ID

11690944

Incident

Oct 8, 2021

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)

NHTSA ID

11683029

Incident

Aug 16, 2025

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.

NHTSA ID

11663118

Incident

May 26, 2025

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.

NHTSA ID

11663035

Incident

May 21, 2025

Mileage

51,000 mi

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.

NHTSA ID

11651999

Incident

Mar 30, 2025

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.

NHTSA ID

11642345

Incident

Jun 23, 2024

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.

NHTSA ID

11634415

Incident

Aug 28, 2024

Mileage

69,000 mi

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.

NHTSA ID

11631795

Incident

Dec 14, 2024

I was driving and a message "engine popuslison reduce" appeared and i was not able to drive at the speed of traffics which was unsafe.

NHTSA ID

11625812

Incident

Nov 15, 2024

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)

NHTSA ID

11619628

Incident

Oct 14, 2024

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!!

NHTSA ID

11614323

Incident

Aug 30, 2024

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.

NHTSA ID

11613521

Incident

Jul 21, 2024

lost power when battery power used up and gas engine would not switch over on highway. car would not re-start and died in the middle of highway

NHTSA ID

11611994

Incident

Aug 24, 2024

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).

NHTSA ID

11608992

Incident

May 18, 2024

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.

NHTSA ID

11601525

Incident

May 26, 2024

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.

NHTSA ID

11592372

Incident

May 26, 2024

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.

NHTSA ID

11591307

Incident

May 8, 2024

Mileage

55,000 mi

My 2018 Chevy Volt displayed a warning message of "Propulsion Power is Reduced" on the dash when I started the car in a parking garage on Saturday, March 9th around 10am. The car would not drive normally and made a strange noise. I had to stop and start the car six or so times before it drove normally for me to get home. Had this happened at high speed, it could have caused an accident or worse. I contacted the local Rockville, MD Chevrolet dealership and they ran the diagnostic test on the BECM and HPCM2 systems and performed battery capacity reset. I do not believe this software reset will correct the technical issue. According to the dealership records, such a software reset was performed in 2021 by the previous owner before we purchased the car second hand in July, 2022. The dealer would not replace the BECM unit but there is supposedly a special coverage bulletin issued by General Motors. We need the unit replaced ASAP for safety.

NHTSA ID

11578171

Incident

Mar 9, 2024

While driving, an engine warning "Reduced propulsion Message" came on. Then it said " Engine Unavailable". The car would not go to gas engine. We panicked as we were 20mi from home and only had a few miles of electric left. I was able to drive to the nearest Chevrolet Dealership. It has been sitting there parked for 2 months. Uncharged. We are told that the problem is the EGR valve but no part is available anywhere. It is a known problem but GM has no parts available to fix. I am not getting any answer as to how long it may take to get the part. Meanwhile, I am without a vehicle. I only have approx 25,000 on the car. We have not been given a replacement car or been given any clear response from GM or the Dealership as to how long this may take to locate a part.

NHTSA ID

11576337

Incident

Dec 20, 2023

Early on the week of November 9th my car displayed a message that there was "Low propulsion power - engine not available." Upon returning home and parking the car it started without incident the following day. On November [XXX], my vehicle stated "Low propulsion power - engine not available" but this time the car shut down completely leaving me unable to return home. I had the car towed to Fairway Chevrolet for repairs. The service technician indicated that the catalytic converter needed to be replaced and the part was out of stock and would take 3 weeks to become available. No rental or loaner car was provided. On November [XXX] I was told that my car was fixed and it would be able to be picked up. I picked up the car and parked it at home and drove the car I was currently renting to California for the Thanksgiving holiday. Upon returning home, I returned my rental and returned to my car. The car behaved normally but after driving down a busy roadway for less than 2 miles the "Low propulsion power - engine not available" message reappeared and the car shut off IMMEDIATELY. This is horrifyingly dangerous especially considering the speed and location of where I was driving. I had the car towed to Fairway Chevrolet but didn't speak to anyone until the morning. In the morning I called in and explained what happened and stressed the safety fact that my car was returned and malfunctioned in a very dangerous way. The tech said that they were going to perform a diagnostic which they were going to charge me for, even though the original repair did not fix the defect. Fairway performed the diagnostic and stated they need to clean the engine bay and run a separate diagnostic of the brake system. These total more than $1.6k out of pocket and are not related to the power deactivating while in motion. My car is still at Fairway as they have not started the repairs and I am still self paying for a rental car. Fairway is uncooperative and refuse to check into the propulsion INFORMATION REDACTED PURSUANT TO THE FREEDOM OF

NHTSA ID

11573665

Incident

Nov 9, 2023