Chevrolet Volt engine failure problems

Filed Dec 6, 2025 · Engine, Fuel system · CA

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.

Filed Dec 2, 2025 · Electrical · 129,000 miles · GA

The contact owns a 2018 Chevrolet Volt. The contact stated that while attempting to start the vehicle, the engine failed to turn over as intended. Additionally, the vehicle would not charge when connected to a charger. The check engine warning light illuminated. The vehicle was taken to a local dealer, where the BECM was reset. The vehicle was repaired; however, the check engine warning light remained illuminated. In addition, the contact stated that the message "Reduced Power" was displayed on the instrument panel. The vehicle was taken back to the same local dealer where it was diagnosed, and determined that the BECM needed to be replaced. The vehicle was not repaired due to the cost. The contact related the failure to an unknown Chevrolet recall; however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 129,000.

Filed Oct 27, 2025 · Engine · 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.

Filed Sep 14, 2024 · Engine, Fuel system · CA

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.

Filed May 30, 2024 · Electrical, Engine · CA

Driving at freeway speeds when suddenly the cars propulsion power failed and I went from 75mph to 45mph with no warning and no way to accelerate. Happened multiple times even after pulling over and turning the car on and off. I was told by the dealership that was a gas engine part and that I could drive it on the electrical engine only. When attempting to drive on the electrical engine, I received a notice of engine failure and had to coast into the driveway of a dealership. I was told the engine “could explode” if I continue to drive it

Filed Mar 8, 2024 · Brakes · CT

Main Issue: Ongoing issue with stuck caliper causing the pads and wheels to overheat increasing the tire pressure to dangerous levels. The regenerative braking system is actually very effective in slowing the car when driven in L mode. If driven smartly, driver rarely have to use a lot of force using the physical brakes and rotors. Three times now, I have had issues where the front calipers were seized and the brakes were stuck causing the wheels to have visible smoke, odors and extreme temps. Perhaps they are not being used as much as normal brakes but service was done at the dealership on both cases, only to have the issue return within a year on a low mileage car. Looking at online forums, this appears to be a common issue with the Volt. Often the High Pressure Accumulator (HPA) is not properly reset during a brake job. [XXX] I have had other non EV cars with regular brakes that worked fine for > 50k miles before service, so there is clearly an issue here. Ironically, as these brakes caliper/pistons/rotors are less used due to regen, the chance of them getting stuck seems to be an issue when they are actually engaged leading to dangerous conditions. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Dec 18, 2023 · Electrical · 20,000 miles · CA

The contact owns a 2017 Chevrolet Volt. The contact stated while driving 65 MPH, the Hybrid battery drained; however, the engine failed to activate as needed. Due to the failure, the vehicle stalled, and the contact coasted the vehicle to the shoulder of the highway. Due to the failure, the vehicle was initially towed to the residence then to the dealer. The vehicle was kept in dealer possession where repairs were made to the ECM (Electrical Control Module). Since the repair, the contact stated that the vehicle intermittently failed to start up while depressing the START/STOP button. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 20,000.

Filed Dec 14, 2023 · Electrical · 100,000 miles · IL

The contact owns a 2012 Chevrolet Volt. The contact stated while driving approximately 50-60 MPH, the Engine Failure, Mountain Mode Not Available, Battery at Zero Percent, Propulsion Power Reduced, and High Voltage messages were displayed. The check engine warning light illuminated. The vehicle then inadvertently decelerated to 30-40 MPH. The contact pulled over to the side of the roadway and turned off the vehicle. After several attempts, the vehicle was able to restart. The vehicle was taken to the dealer, where it was diagnosed that the high-voltage battery pack needed to be replaced. The vehicle was not repaired. Additionally, the contact stated that the vehicle failed to pass the yearly vehicle inspection. The dealer loaded sample data into the computer and then drove the vehicle for 50 miles before the vehicle passed inspection. The manufacturer was not made aware of the failure. The contact related the failure to the federal safety agency Action Number: PE23022 (Electrical System). The failure mileage was approximately 100,000.

Filed Dec 3, 2023 · Fuel system · NC

The car stopped working at a stoplight while I was driving my son to school. There was no warning other than a "Propulsion power is reduced" message seconds before it stopped working. After turning it off and back on, I got the car to limp out of traffic. By the time the tow truck arrived an hour later, we could barely get it to go into neutral to tow it. After towing it to the dealer, they replaced the engine control module. Since then, it has been working fine.

Filed Jan 21, 2022 · Electrical, Engine · WV

I received a 'Reduced Propulsion' message along with a check engine light and that progressed to a 'Engine not Detected" message and stranded along the interstate in a dangerous situation. Had it towed to a dealership which had a technician which could work on a volt - he replaced the Engine Control Module fuse which "fixed" the car for about 15 miles and then the 'Reduced Propulsion' error with the Check Engine light appeared. Technician said something must be shorting out the fuse. Dangerous situation.