2018 Chevrolet Volt fuel system problems

Filed Nov 2, 2026 · Electrical, Engine · UT

My 2018 Chevy Volt is experiencing the EXACT same symptoms as GM's Battery Energy Control Module (BECM) Warranty Extension Program N232432680 AND Program N202307990 AND TSB 19-NA-206. My vehicle falls within the guidlines of affected vehicles, yet GM will not honor their program specifications. My vehicle has stalled while driving on the highway, not started, reduced power, and will not charge or depletes a full charge within 30 minutes. I stalled while driving 75 mph on a freeway. My car also would not allow me to shift into park while returning home, then tells me to shift into park when I am trying to tleave for work. GM tells me that "Your VIN does not fall within the repair requirements, even though your vehicle exeriences everything taking place and meets the standard requirements." The dealership tells me that I have to take it up with GM. I have children I drive to school, I drive to work, and I do not think that something of this nature, with the EXACT SAME symptoms that GM claims is happening, with the EXACT SAME codes related to the issue, with very possible safety issues being experienced should be overlooked. This has been happening for months, and I have been trying to explain to GM and the service department at the dealership what is going on, they have proof of what is going on, but I do not qualify because of my VIN even though, as stated by GM, "This specific program extends coverage to 15 years or 150,000 miles regardless of whether your specific VIN shows an active safety recall."

Filed Oct 27, 2026 · Electrical, Fuel system · WI

My 2018 Chevrolet Volt LT (VIN [XXX]) suffered a Battery Energy Control Module (BECM) failure at 142,185 miles. Gandrud Chevrolet in [XXX], diagnosed the failure, citing GM Technical Service Bulletin 18-NA-261 and diagnostic codes U2619, U2620, U2621, U2622, U2623 and U2624. The dealer replaced the BECM (part 24296900), programmed it, and performed associated work. The repair was completed XXX. The invoice was $3,160.70; I am seeking $3,066.25 in reimbursement for the qualifying repair expenses. GM denied coverage because my VIN is excluded from Special Coverage XXX, despite the dealership-confirmed BECM failure. I pursued the matter through GM Customer Assistance (case 106790207), mediation (case XXX), and Wisconsin DATCP (case XXX). GM maintained that the special coverage does not apply to my VIN. the federal safety agency previously investigated BECM failures under PE23022. However, owners continue to report similar problems in 2026, including reduced propulsion, inability to drive or restart, charging failures, and reported BECM failures. I ask the federal safety agency to review these 2026 complaint records alongside mine: XXX A sudden loss of propulsion can leave a vehicle unable to maintain speed or move safely with traffic, creating a potential crash risk. I am concerned that VIN-based coverage exclusions may leave vehicles susceptible to the same failure without an effective remedy. Please review these reports collectively, reassess whether the current coverage captures the affected vehicles, and determine whether further investigation, expanded coverage, or a safety recall is warranted. I can provide my repair invoice, diagnostic documentation, and GM’s written denial. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Oct 24, 2026 · Electrical, Fuel system · UT

While driving through a canyon to get home, my check engine light came on and I saw the message "Propulsion Power Reduced" on my dash. The speed limit on that road is 65 mph, and I lost power going up a hill and went from 65 mph on cruise control to 48 mph. There are a lot of cars on that road, and it could've caused a serious accident. My vehicle does exactly what the GM extended coverage describes and is within the parameters, but somehow my vehicle does not qualify. This could've been bad on that road is it was raining or snowing.

Filed Sep 28, 2026 · Fuel system · CA

2018 Chevy Volt LT. Diagnosed with a bad battery section on September 9, 2026. Warranty part number # 24060120 ordered by dealer. Status September 28, 2026 - Part back-ordered / No ETA. Dealer refuses to provide a loaner car while waiting for the part.

Filed Sep 25, 2026 · Electrical, Fuel system · OH

FAILURE SUMMARY & SAFETY RISK: While operating in live traffic, the vehicle experienced a sudden loss of motive power and entered a "Propulsion Power Reduced" failsafe mode, creating a severe rear-end collision hazard. The vehicle is currently grounded and remains available for inspection upon request. WARNING SYMPTOMS & DIAGNOSTIC CODES: The instrument cluster illuminated the Malfunction Indicator Lamp (Check Engine), the ABS warning indicator, and displayed a persistent "Propulsion Power Is Reduced" message. A diagnostic trouble scan confirmed active high-voltage communication failures and powertrain faults: U2603 (Lost Communication with Hybrid/EV Battery Interface Control Module), P25A2 (Brake System Control Module Requested MIL), and ABS code C0500-00. PRIOR HISTORY & FAILURE TO CURE: This identical high-voltage Battery Energy Control Module (BECM) failure previously occurred in December 2025 at 97,808 miles and was presented to an authorized Chevrolet dealership for repair. The facility claimed the vehicle was repaired, but the exact same catastrophic high-voltage failure recurred in under 4,000 miles (at 101,635 miles). MANUFACTURER POLICY & OBSTRUCTION OF REPAIR: General Motors recognized this hazardous defect under Special Coverage N232432680 (covering BECM replacement for 15 years/150,000 miles at $0.00 cost). This policy links to GM Master Bulletin 07-00-89-037S mandating direct-bill Courtesy Transportation for grounded safety defects. Despite this, when presented for warranty repair, the authorized Chevrolet dealership explicitly refused intake and refused to honor the transportation mandate, stating on the record: "Yes, I do decline". GM Corporate (Case 98734634) admitted coverage applied but failed to compel franchise compliance, leaving a dangerous, immobilized high-voltage hybrid vehicle stranded without access to safety-mandated repair bays.

Filed Aug 27, 2026 · Engine, Fuel system · TX

I was driving back from [XXX] on XXX, when I received a "propulsion power limited" message on my dash with a check engine light. I pulled off to a nearby gas station and tried to scan the code to figure out what was going on when I then received the message "Engine unavailable" and the car shut off. I checked the fuse box and found that the F03 Fuse had blown. I replaced the fuse and attempted to start the car again. It began normally, but then after driving 10 feet, I received the "engine unavailable" message again with a check engine light and the car no longer had power and I had to coast into a parking spot. I checked the fuse again and found it was blown. If I had not stopped in the gas station, I would have been stranded on the side of the highway, or worse yet, I would have stalled out on the highway and potentially got hit. I had my car towed to a dealership who eventually completed their inspection of the car on XXX and determined that the EGR Valve had failed (the servo motor burned out and blew the F03 Fuse). This is a well known issue on the 2nd Generation of Volts and it is likely faulty servo motors in the EGR valves. The Dealership even included in its financial assistance request to Chevy on my behalf that the EGR valve failure is a known issue. When asked if there was any preventative maintenance suggested to prevent the EGR valve from failing, the service technician indicated that there wasn't anything that I did as the end user to cause the problem. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Aug 17, 2026 · Fuel system · OR

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.

Filed Aug 5, 2026 · Electrical, Engine · TX

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

Filed Jul 31, 2026 · Electrical, Fuel system · UT

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

Filed Jul 28, 2026 · Fuel system · MI

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.