CHEVROLET VOLT

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

General Motors, LLC (GM) is recalling certain 2013 Buick Verano, Chevrolet Camero, Sonic, and Volt vehicles. The driver-side air bag inflator may explode during deployment due to a manufacturing defect.

Risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

SEAT BELTS:REAR/OTHER

General Motors LLC (GM) is recalling certain 2018-2019 Cadillac CT6, Escalade ESV, Chevrolet Suburban, Volt, and GMC Yukon XL vehicles. Certain second-row or third-row rear seatbelts retractor assemblies may not automatically lock when the seatbelt is fully pulled out of the retractor, possibly preventing a child seat from being properly secured. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection."

Risk: If the child seat is not properly secured in the event of a crash, it can increase the risk of injury.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

General Motors LLC (GM) is recalling certain 2018-2019 Chevrolet Equinox, Impala, Cruze, Volt and Bolt EV vehicles, GMC Terrain vehicles, Buick Lacrosse and Regal vehicles, Cadillac XTS and XTS Professional vehicles and 2018 Chevrolet Malibu vehicles. The rear brake caliper pistons may have an insufficient coating causing gas pockets to form, potentially reducing rear brake performance.

Risk: A reduction of braking performance can increase the risk of a crash.

HYBRID PROPULSION SYSTEM

General Motors LLC (GM) is recalling certain 2013 Chevrolet Volt vehicles. An update to the Hybrid Powertrain Control Module 2 (HPCM2) may have disabled the cell balancing function causing a low-voltage condition.

Risk: If the voltage drops, the vehicle may lose propulsion, increasing the risk of crash.

AIR BAGS:FRONTAL

General Motors LLC (GM) is recalling certain 2015-2016 GMC Canyon and Chevrolet Colorado, and 2016 Chevrolet Volt vehicles. The driver's frontal air bag may improperly inflate during second-stage deployment in the event of a high speed crash.

Risk: An improperly inflated air bag increases the risk of injury in a crash.

ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

General Motors LLC (GM) is recalling certain model year 2011-2013 Volt vehicles manufactured August 25, 2010, to June 26, 2013. If the driver exits the vehicle without turning off the electrical system, the battery may drain low enough that the gasoline engine will automatically start itself to recharge the electric battery.

Risk: If the engine runs for an extended period of time in an enclosed space, there may be a build up of carbon monoxide, increasing the risk of personal injury.

STEERING

General Motors LLC (GM) is recalling certain model year 2014-2015 Chevrolet Cruze vehicles manufactured November 8, 2013, to March 12, 2015, and 2015 Chevrolet Volt vehicles manufactured April 11, 2014. In the affected vehicles, the inner tie rod may not be tightened to specification allowing the tie rod to separate from the steering gear.

Risk: Separation of the tie rod from the steering gear could result in the loss of steering, increasing the risk of a crash.

TIRES

On all (4) tires, there is cracking in the sidewalls in a line about 2 inches above the tire bead around each tire. Approximately 19K miles on these tires. Manufacture and supplier/seller (Priority Tire) both sent multiple photos of issue, tread depth, etc. and then denied any warranty on the tires due to 'Improper Usage' (reply below) I asked the supplier/seller and the manufacture what that means and no reply. Tires are consistently rotated by myself and tire pressures consistently maintained. I am [XXX] and don't race or off road my Volt. This could be a potential safety issue if one or more tires were to fail unexpectedly. Please see photos and thank you for your help. Hello, We are reaching out regarding your warranty request. Unfortunately, the manufacturer/supplier declined your warranty request, as they inspected the issue, and determined that the cause of damage on your tire is improper usage. We are sorry that we could not help you any further. Please let us know if you have any other questions. Thank you for your understanding, and once again, apologies for the inconvenience. Dave B Customer Service Representative INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

FUEL/PROPULSION SYSTEM

Check engine light came on car was able to start but the cluster started reading the battery being full with a charge. And was having trouble starting. Fast forward a day I get a propulsion system reduced warning on the dash as I’m entering the highway and the car fails to stay on I’m able to pull it to the shoulder and I cannot get the car to start. Get towed home throw it on the charger and the dash says unable to charge. swap the 12v (checked it and it died) thinking that might fix the problem since the car was able to power on but not start. To no avail through my code reader and code p1e00 code. Took it to my local dealer and was told id need replace the becm… and was quoted 33xx for the repair. Had any of this happened while I was on the freeway I might not have been able to make it to the shoulder potentially putting myself and others on the road and a possibly fatal situation.

ELECTRICAL SYSTEM

Check engine light came on car was able to start but the cluster started reading the battery being full with a charge. And was having trouble starting. Fast forward a day I get a propulsion system reduced warning on the dash as I’m entering the highway and the car fails to stay on I’m able to pull it to the shoulder and I cannot get the car to start. Get towed home throw it on the charger and the dash says unable to charge. swap the 12v (checked it and it died) thinking that might fix the problem since the car was able to power on but not start. To no avail through my code reader and code p1e00 code. Took it to my local dealer and was told id need replace the becm… and was quoted 33xx for the repair. Had any of this happened while I was on the freeway I might not have been able to make it to the shoulder potentially putting myself and others on the road and a possibly fatal situation.

ENGINE

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)

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)

POWER TRAIN

I am writing regarding my Chevrolet Volt, which suffered the very common Battery Energy Control Module (BECM) failure that your office already investigated and which resulted in GM being required to extend coverage under special warranty reference: MC-10251431-0001 . Despite this, Chevrolet is refusing to cover my repair. Their reasoning: because my Volt was originally purchased in California, they claim it falls under CARB rules—but now that I live in Arizona, they insist neither California’s coverage nor the NHTSA-ordered special coverage applies. In effect, my vehicle has been trapped in a paperwork loophole GM is exploiting to avoid responsibility. This response is not in the spirit of your findings. The defect was not caused by geography, state lines, or ownership history. The BECM is a manufacturer defect, and it failed for the same reason thousands of others have failed: poor design and inadequate durability. Whether the car was first sold in California, Colorado, or Kansas is irrelevant—the failure is GM’s, and the repair obligation should be GM’s as well. By denying coverage on a technicality, Chevrolet is undermining the very purpose of the extended coverage you required: to protect owners from footing the bill for a well-documented, widespread, and unsafe defect. Their position leaves me, and others like me, bearing the costs of GM’s engineering failure. I ask that NHTSA review GM’s handling of these claims and require them to honor the extended coverage as intended, without hiding behind jurisdictional loopholes.

FUEL/PROPULSION SYSTEM

Propulsion power reduced and check engine light came on my 2017 Chevy volt - been happening a few times now the last week

ENGINE

I was driving my car from Houston to Dallas when I got the "reduced propulsion" message and a check engine light. When I first saw the reduced propulsion issue I thought it might be related to the BECM issue again since I had already experienced that problem before. In the last few minutes of my trip the AC started to get hot and when I checked the coolant temperature I noticed it was around 240 - 255 F. I hadn't noticed it since there was no warning light for high temperature which I am used to with other cars. I'm not sure of the full extent of the issues yet, but I know for certain that the EGR valve has failed completely at about 71,500 miles. This is with very few miles on the actual ICE. I typically only use the ICE for a few hundred miles of driving each year. Fortunately for me, even though the CEL came on for the reduced propulsion I was able to reach my destination. However, when I went to leave, the car left me stranded as the ICE would shut down after a few minutes of running. The propulsion system is reduced and the engine becomes unavailable. Only the battery power will allow the car to drive. The F3 fuse in the EGR circuit blows if the engine is activated, and has happened multiple times already confirming the EGR issue. I have additional check engine lights that are a result of the EGR failure to circulate coolant properly. Below is a list of all the CEL codes that were pulled: P06DB P0030 P0031 P0403 P0405 P0443 P0458 P0489 P0597 P0598 P06DA P0AC4 P0135 P0AC4 P16E0 Looking into this issue I found that this is an one of the most common failures in the Chevy Volts but is no longer covered under the vehicle warranty and no bulletins posted for an extended warranty other than the BECM failure. This failure is so prevalent that I am surprised it is not.

POWER TRAIN

I was driving my car from Houston to Dallas when I got the "reduced propulsion" message and a check engine light. When I first saw the reduced propulsion issue I thought it might be related to the BECM issue again since I had already experienced that problem before. In the last few minutes of my trip the AC started to get hot and when I checked the coolant temperature I noticed it was around 240 - 255 F. I hadn't noticed it since there was no warning light for high temperature which I am used to with other cars. I'm not sure of the full extent of the issues yet, but I know for certain that the EGR valve has failed completely at about 71,500 miles. This is with very few miles on the actual ICE. I typically only use the ICE for a few hundred miles of driving each year. Fortunately for me, even though the CEL came on for the reduced propulsion I was able to reach my destination. However, when I went to leave, the car left me stranded as the ICE would shut down after a few minutes of running. The propulsion system is reduced and the engine becomes unavailable. Only the battery power will allow the car to drive. The F3 fuse in the EGR circuit blows if the engine is activated, and has happened multiple times already confirming the EGR issue. I have additional check engine lights that are a result of the EGR failure to circulate coolant properly. Below is a list of all the CEL codes that were pulled: P06DB P0030 P0031 P0403 P0405 P0443 P0458 P0489 P0597 P0598 P06DA P0AC4 P0135 P0AC4 P16E0 Looking into this issue I found that this is an one of the most common failures in the Chevy Volts but is no longer covered under the vehicle warranty and no bulletins posted for an extended warranty other than the BECM failure. This failure is so prevalent that I am surprised it is not.