2018 Chevrolet Volt fuel system problems

FUEL/PROPULSION SYSTEM

I was driving on an interstate in Seattle, and the car completely died. A check engine light went on. I had to roll into the shoulder and call for a tow to the dealership's service department. Here is what they found: ----60GCZ ENGINE REPAIR DIAG/ customer reports the ses lamp is on with reduced propulsion message displayed. Check and advise. 1. Tested vehicle and verified reduced propulsion power message and SES light. Scanned vehicle for codes and found multiple P0489, P0030, P0031, P0132, P0135, P0137, P0443, P0458, P0597, P0598, P06DA, P06DB, and P103C. Traced back to no power on circuit 5293. Traced back to blown 15-amp fuse 3 of under hood fuse block. Found bulletin #24-NA-080 stating this can be caused by a short in the EGR valve. Tested circuit 5293 and found short at the EGR valve. Advise EGR valve and cooler replacement then retest.---- We disconnected the EGR valve, which means we are driving only on gas, not electric. We cannot charge it anymore. The cost to replace the valve and cooler is over $4k because Chevrolet does not make the vehicle anymore or the EGR valve part apparently. This is a SIGNIFICANT safety hazard if the car is going to simply die suddenly. It is a miracle I did not get hit.

NHTSA complaint #11757544 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11755062 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The Vehicle had a the BECM fail at 64,000 miles. This is a known issue that GM still refuses to recall, and is refusing to warranty

NHTSA complaint #11754026 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

I was investigating a thumping sound coming from the vehicle when going over bumps. I discovered that the left fuel tank strap had completely broke into two pieces and was no longer holding up the tank. The fuel tank straps are not readily viewed on the vehicle until you lower/remove the underbody aerodynamic material. It appears that the underbody aerodynamic material may have been contributory by retaining dirt and trapping moisture in contact with the tank straps. The failed tank strap parts are available for inspection. No other indication of the failed tank strap other than the minor noise and no other inspections have been performed on the failed component.

NHTSA complaint #11753393 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The Battery Energy Control Module (BECM) failed. Before repair, the check-engine light appeared intermittently, the vehicle sometimes had difficulty starting, and the indicated electric range could suddenly drop from about 30 miles to zero despite a charged high-voltage battery. When this occurred, the gasoline engine started unexpectedly. The air conditioning also intermittently blew warm air until the vehicle was restarted. These symptoms created a safety concern because propulsion mode and indicated range could change without warning, and the vehicle could fail to start in traffic or another unsafe location. An authorized Chevrolet dealer confirmed the problem. The dealer retrieved DTCs U2624 and U2629, performed circuit testing, and diagnosed an internal short in the BECM causing loss of communication with high-voltage battery modules. The dealer stated this failure caused the warning light, starting issue, sudden loss of indicated battery range, and air-conditioning symptoms. The BECM was replaced and programmed after removal of the high-voltage battery assembly. The warning light first appeared about one month before repair, with the other symptoms becoming more apparent in early July 2026. The vehicle had approximately 80,918 miles when inspected. The failed component was retained by the dealership as a core and is not available to me for inspection. To my knowledge, the vehicle was not separately inspected by police, insurance, or GM engineering personnel. My vehicle was excluded from GM Special Coverage N232432680 even though it is a 2018 Chevrolet Volt with the same confirmed BECM failure addressed by that program and NHTSA investigation PE23022. I paid $3,970.56 for the repair. I am filing this complaint because this defect can cause no-start, loss of indicated battery range, warning lights, unexpected propulsion changes, and potentially reduced propulsion, while some affected 2016–2018 vehicles appear excluded from the special coverage.

NHTSA complaint #11752752 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The car suddenly lost power and produced error messages on the screen. I had to quickly change lanes to get out of traffic on the highway. My dealer diagnosed the issue as a BECM malfunction and quoted a repair cost of approximately $3500. However, due to my car originally being registered in California, this failure is not covered under GM Special Coverage Bulletin N232432680 (issued March 2024), which provides an extended warranty for BECM issues on affected 2016-2018 Volts up to 15 years or 150,000 miles. My VIN does not qualify for this coverage despite the vehicle being within the model years affected by known BECM soldering/connection failures. This appears to be part of a broader pattern of BECM defects in 2016-2019 Volts that can lead to sudden loss of propulsion, as previously investigated by NHTSA. GM should extend coverage or issue a recall for all affected vehicles, as this defect compromises vehicle safety and leaves owners with expensive out-of-pocket repairs for a known issue.

NHTSA complaint #11748652 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

I was driving my 2018 Chevy Volt at about 30 mph on EV mode. The battery was at 50%, the car was performing normally. Then the battery jumped to 100%, the check engine light came on, and the vehicle lost power. I was in rush hour traffic and unable to get the vehicle to go faster than 5-10 mph. I switched to "normal" mode to engage the gasoline engine, hoping this would help but it did not. The gas engine RPM fluctuated wildly and did not restore the ability to accelerate the vehicle. I was still unable to go faster than 5-10 mph. I was a few blocks from home and managed to get home safely. The engine code was P1E00. I put the vehicle on the charger and it seemed fine the next day. This exact situation I ran into - reduced engine power - is addressed in Special Coverage N232432680, which includes this vehicles VIN. I took the car to the GM dealer today and they are telling me that the car is fine, they can find no problems. I mentioned that this issue is covered under Special Coverage N232432680, and was told that unless they can reproduce the issue in the shop, that they cannot apply Special Coverage N232432680.

NHTSA complaint #11735155 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The vehicle losses power on high speed, check engine comes on, low propulsion massage displays. Vehicle does not charge. Issues similar to the investigation DCS6812.

NHTSA complaint #11726565 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11716611 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11704006 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Why in operation the car goes into Shift to Park and Also getting a Propulsion Power Reduce

NHTSA complaint #11699315 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 11/7/25: Propulsion Power Reduced and check engine light again. Vehicle is at GM dealer service center.

NHTSA complaint #11699163 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11693560 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11693450 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11687927 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11683029 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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)

NHTSA complaint #11678250 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11663118 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11661821 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Vehicle produced error without any warning about propulsion system no longer working shortly after low fuel warning when tank is fuel and engine fails and vehicles comes to a crawl.

NHTSA complaint #11652969 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Issue Summary: The Chevy Volt has experienced recurring electrical problems, including the "Shift to Park" message, loss of power, and dead 12V battery. The vehicle had to be towed to the dealership three times due to these issues. One incident involved a power loss while driving at 65 mph, which caused a near-miss with a semi-truck, posing a significant safety risk. Warranty Status: The additional warranty was purchased, but only one of the three incidents occurred while the vehicle was under warranty. Safety Concerns: The repeated electrical failures, especially while driving at high speeds, raise serious safety concerns

NHTSA complaint #11652364 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11651999 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Yesterday, my daughter was driving on [XXX] in Seattle traveling around 65mph when the vehicle lost power and reported the error of "shift to park", "Propulsion reduced" and "StabiliTrak failure". Luckily, she coasted to an off-ramp and safely put the vehicle in park. Thankfully she was not involved in an accident, but was very shaken by the experience. After doing some research it seems that the Chevy Volt has a known issue with the BECM and GM has failed to issue a recall, putting thousands of lives at risk. After turning the vehicle on and off several times, she was able to get it started and with minimal propulsion on residential streets was able to return to our house. this morning I dropped the vehicle at our local GM dealer for diagnosis and repair, but wanted to file a report, to hopefully prevent this from happening to another unsuspecting driver/child. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11642763 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE:STORAGE:EVAPORATIVE EMISSIONS:HOSES/VALVES/SENSORS

The contact owns a 2018 Chevrolet Volt. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed that the EVAP pipe was rubbing against the air conditioning hose connector. The dealer informed the contact that the vehicle was previously repaired under GM Campaign Number: N192273600; however, the failure persisted. The vehicle was not repaired due to the cost. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 84,800.

NHTSA complaint #11642577 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

Randomly getting Propulsion power is reduced and loss power while driving. Been force to pull over to the side on the freeway to restart the car.

NHTSA complaint #11641591 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The BECM (Battery Electric Control Module) failed in November of 2023. Mountain Chevrolet has had my vehicle since then, claiming to be unable to find replacement battery module. The vehicle is available for inspection at Mountain Chevrolet (it has been left unlocked, unprotected, and exposed to the elements for almost 15 months now). When the BECM failed, the vehicle lost virtually all power and slowed dramatically from highway speeds to ~20 mph. There were no warnings prior to the failure.

NHTSA complaint #11637803 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11631795 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The issue started with a forward push while lowering my speed while coming to a stop. It then progressed to a trembling engine. Then it progressed to the car struggling to effectively switch from electric to gas and back. It then would only be usable on electric range and the engine would not start and would be greyed out. Now, it only works on engine mode, it uses fuel like a pick up truck, it loses power while driving due to trying to switch to electric mode and back, and it struggles to accelerate. It will do it while idle as well as while driving 45mph and up. It barely has any propulsion power and I have to turn my hazards on any time I am going to accelerate. If I brake hard the engine will shake violently and then shut off. I then have to switch gears from drive to park or neutral to park to drive to reengage the engine. Recently it has turned on all the accessories but the ev and the gas is greyed out and there is zero propulsion power. I replaced the 12v battery thinking it might have been dying and it still has the same issue. I read about the class action lawsuit for the BCEM and have made an appointment the dealership but when I told them what was wrong with it the said we need to wait for the diagnostics.

NHTSA complaint #11631693 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

On 9/18/24 I was driving my Chevrolet 2018 Volt on a freeway, traveling at approximately 55 mph while starting to exit the freeway. In the middle of fast-moving traffic, on the freeway offramp and starting to decelerate, the car suddenly displayed a message saying "Propulsion Power is Reduced." A micro-second later, the displayed message changed to read "Action Required: Shift to Park" and in that moment I lost control of the car's powertrain. I continued to break, coming to a slow stop in the middle lane of a multi-lane offramp, with other cars speeding past and around me. I attempted to power the car down and reboot it, moving the gear shift into "Park" position as instructed, but nothing changed. The car remained totally inoperable. I was on a slight decline and noticed the car moving forward pulled by gravity, so I steered the car to the farthest right of the offramp/parallel street, where I put my hazard signals on and requested the car be towed to a mechanic. I was endangered because the car lost entire propulsion while in the middle of fast-moving freeway traffic, and fellow motorists were endangered as well. I have learned that this same behavior occurs routinely with 2nd generation Volts; that there is a special bulletin related to the car's BCEM *and* a related class-action lawsuit posed against GM/Chevrolet. I requested Chevrolet take preemptive action to repair the BCEM, as I am fearful the issue will repeat and cause additional danger to myself and fellow motorists, but Chevrolet says they cannot repair the part until it is diagnosed as defective... which will occur when/if the part fails again, and I'm already in danger.

NHTSA complaint #11617333 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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 complaint #11614323 — an unverified report by a vehicle owner.