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.

- Shrewsbury, MA, USA

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. the GR seems to have bad soldering and blows the fuse #3.

- Falcon Heights, MN, USA

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.

- Marblehead, MA, USA

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

- Churchton, MD, USA

Reduced propulsion power and check engine light. EGR valve failure per mechanic. Part has been on a global back order for 1.5 years. The car will not pass emissions testing and can blow a fuse that will make the car inoperable. The part is also costly at $2400 without labor costs. My car has 83,000 miles, is well-maintained and only 7 years old and now I can-??t drive it or sell it.

- The Hills, TX, USA

I was driving on the interstate when my check engine light came on and the car told me it was going into reduced power mode. I then had to limp my car along on the interstate till I could get off the road, many close calls going 45-50 mph on a 70 mph road.

- Menomonie, WI, USA

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

- Pleasanton, CA, USA

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)

- Eden Prairie , MN, USA

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.

- Largo, FL, USA

CEL came on in January 2024. Brought to dealer and diagnosed with failed EGR valve. EGR valve replacement part is not available from manufacturer. No information on when EGR valve might be available has been offered from dealer or manufacturer. Valve must be replaced to pass emissions inspection in December.

- Niskayuna, NY, USA

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

- Wilmington , NC, USA

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

- Jacksonville, NC, USA

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.

- Monkton, MD, USA

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

- Las Vegas, NV, USA

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

- Durham, NC, USA

The contact owns a 2017 Chevrolet Volt. The contact stated that the vehicle was lagging and hesitating before accelerating. The contact stated that an excessive amount of pressure was needed to depress the accelerator pedal while driving. The contact stated that the vehicle had experienced reduced Hybrid propulsion. The contact stated that the check engine warning light was illuminated. The failure was intermittent. The vehicle had not been taken to the dealer. The vehicle was not diagnosed or repaired. The manufacturer had not been made aware of the failure. The failure mileage was 140,000.

- Los Angeles, CA, USA

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.

- Wakefield, MA, USA

While making a 90 mile drive on 7/20, after having depleted the primary battery charge and switched to hybrid mode, a "propulsion power is reduced" warning appeared on the console, along with the Check Engine Light. Other than somewhat reduced power (max displayed of ~40-50 kW), performance otherwise seemed unimpeded. Contacted local dealership to schedule service for earliest available date of 7/26. Car made return 90 mile trip on 7/21 without issue additional issue ("propulsion power is reduced" message remained.) Service identified "numerous codes", but replaced a fuse known to result in the above issue and observed no other issues. Car was driven purely on battery at that time, and for the intervening time until a 170 mile drive on 8/2, where the message and Check Engine Light reappeared, again after battery charge was consumed and car switched to hybrid power mode. Dealership was again contacted to schedule service, slated for the morning of 8/7 (tomorrow, as of this writing). Car reached its destination without further incident. During return 170 mile trip on 8/5, traveling on the highway, car abruptly alerted that the engine was no longer available and entered a severely reduced-power mode. Car had been operating in "mountain mode" (conserving some extra battery charge) as a precaution, so we were able safely exit the highway and pull into a local parking lot, at which point AAA was contacted to tow the car the remaining 120 miles home. Upon arriving home, the car was able to pull into the garage without the "engine not available" alert, but still displaying Check Engine Light and "propulsion power reduced" messages. We have come to understand this is a fairly common issue with Generation II Volts and have been advised by other owners to file this report.

- West Bridgewater, MA, USA

10 months ago, I took my vehicle in to the local chevy dealership because the check engine light was on and I had noticed the vehicle seemed to be running rough. I had also seen a message that said the vehicle was running at reduced propulsion. The dealership told me I had a shorted EGR valve which also cause fuse 3 to blow and ordered the part. Then I waited. My vehicle stopped running on the road once. Just died. I had no battery charge remaining either. That was a safety issue for me and anyone who might hit my car because it was on the road. I sat there for a while and then tried to start it. I wasn't far from home and was able to limp home. I waited for months, contacted the Chevy/GM manufacturer and kept in contact with the dealership. Over the next 10 months was told several different things: part not being made, strike affected part manufacture, part and install price was increasing to $3500, can install Chinese part without warranty, dealership had 2 other people waiting for the part like me, part was not covered under any warranty. I was called a couple days ago to hear that there was a GM manufactured part available for my car but it would be $3500. I asked for a reduction in cost since I had waited so long. I was told they could reduce the price by $500. I said I had been quoted $1200 in 2023 when I took the vehicle in. I was told to share anything I had in writing for that. I found my invoice which showed the purchase cost for the parts ($717.80) which I just sent. I received a call today telling me the dealership has the part and will give it to someone else unless I agree to get it done today for $3500; however, since I did not know the part was even here for me, they will wait one more day to hear if the manufacturer will honor the original quote. For the last 10 months, I had no car to drive or could drive it on battery and hope I didn't run out of charge (~50 miles of battery charge) and get stranded on the road again.

- Olympia, WA, USA

[XXX], while driving on [XXX], check engine light came on with reduced propulsion warning. Continued driving to destination without incidence. Did not drive again until [XXX]. [XXX] 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. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

- Baltimore, MD, USA