This bulletin advises the technician to flush the cooling system multiple times if oil has been found in the cooling system and replace the parts that may be contaminated due to oil in system.
full bulletin at NHTSA ↗2016 Chevrolet Volt engine problems
moderate 19 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Complaints
19
Recalls
0
Avg fix
$3,100
What stands out
Among the 6 model years of Chevrolet Volt in our records for engine problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This bulletin advises the dealers to maintain the vehicle stock on hand by doing a full inspection on the vehicles before being sold (prepping) to the customer.
full bulletin at NHTSA ↗This service bulletin advises the tech to check the wiring harness to validate that the harness is not the cause of the check engine light and to replace the EGR to correct a customer concern of MIL Illuminated.
full bulletin at NHTSA ↗This service bulletin provides information on AGM batteries that require less frequent charging in storage.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report the 2016 Volt experiencing catastrophic propulsion failures, with the EGR valve emerging as the dominant culprit. Check engine lights and "propulsion power reduced" warnings appear suddenly while driving—sometimes at highway speeds—forcing drivers to limp home or sit on roadsides. Engine rough-running, harsh acceleration, and overheating follow. Multiple owners waited 5+ months for replacement parts; one owner waited a full year with no resolution. Quoted repair costs range from $2,400 to $3,175. The parts remain on backorder nationwide, and dealers cannot guarantee arrival. Chevrolet acknowledges 10-year/150,000-mile warranty coverage but has not produced replacement parts. Owners report the EGR valve failure is common enough among Gen 2 Volts that it should trigger a recall.
A separate but serious failure involves Battery Energy Control Module (BECM) breakdown, where vehicles suddenly lose all propulsion mid-road. One owner waited seven weeks for a replacement BECM that dealers cannot locate.
One owner reports a sudden internal engine crack causing complete failure with no prior warning. Another owner noted that Recall 16055 (Hybrid Powertrain Control Module reprogramming, performed January 2017) changed remote-start settings without notification, causing engines to run unintentionally in garages—a carbon monoxide hazard.
Same Chevrolet Volt engine reports on nearby years: 2017 · 2018
Failure modes owners describe
EGR Valve Failure
Exhaust gas recirculation valve fails internally, triggering check engine light and propulsion power reduction. Multiple owners report the valve failing suddenly while driving. One owner notes the EGR valve shares a circuit with a water pump, causing the engine to overheat. Failed valves are causing widespread backorder issues, with owners waiting 5+ months for replacements.
When: Varies; one owner at 5 months of ownership; one at ~20 miles into a trip; one during highway cruise at 65 mph
Symptoms owners cite: Check engine light; Propulsion power reduced warning message; Engine running rough or harsh; Reduced acceleration (30-40 mph max); Engine overheating; EV range shows zero despite full charge; Car stalls or switches to limp mode
Codes mentioned: EGR valve failure, Multiple codes in ECM (one complaint)
Repairs/costs cited: Dealership replacement quoted at $2,400 and $3,175.23 in separate cases. Parts consistently on backorder; owners report waits of 5+ months with no arrival estimate. One owner waited a full year with no resolution. Some owners have been suggested to unplug EGR and replace fuse, but this risks further engine damage and emission test failure.
Recalls/TSBs owners mention: One replacement under warranty was performed. Most complaints report 10-year/150,000-mile warranty coverage exists but GM/Chevrolet has not made replacement parts available. One dealer quoted $250 inspection fee if part doesn't arrive. No recall issued despite owner claims it's a common failure on Gen 2 Volts.
Engine Internal Crack (Sudden Failure)
Engine develops sudden internal crack resulting in complete failure, rendering vehicle inoperable. One owner reports the crack was confirmed by dealership inspection and documented. No prior warning signs. Upon failure, low oil and low propulsion error messages appeared.
When: Sudden; no mileage context provided
Symptoms owners cite: Low oil error message; Low propulsion error message; Complete engine failure; No prior warning lights or unusual symptoms
Repairs/costs cited: Engine available for inspection. Full dealership inspection and documentation completed confirming sudden crack.
Recalls/TSBs owners mention: Submitted to GM corporate for warranty review. Dealership verified crack was sudden and not caused by negligence or improper maintenance. Owner suspects defect in emissions-related engine components.
BECM (Battery Energy Control Module) Failure
Battery Energy Control Module fails, causing sudden loss of propulsion and vehicle stops mid-road. One owner reports BECM failure diagnosed after week 7 of waiting for replacement. Another owner experienced similar sudden stoppage mid-road. These failures create serious safety risk on roadways.
When: One complaint at week 7 post-diagnosis; another during normal driving
Symptoms owners cite: EV shows zero miles range despite full charge; Check engine light; Vehicle suddenly stops or loss of propulsion; Rough engine running when ICE kicks in
Codes mentioned: BECM failure
Repairs/costs cited: Dealership unable to locate replacement BECM. One owner reported week 7 of waiting with no parts available.
Recall 16055 - Hybrid Powertrain Control Module Reprogramming (Unintended Consequence)
Recall 16055 reprogramming changed engine remote-start setting from OFF to ON without owner notification. This modification causes engine to run when owner uses remote start to warm up vehicle in garage, creating carbon monoxide buildup hazard.
When: January 5, 2017 (recall performed)
Symptoms owners cite: Engine runs unintentionally when remote start activated in garage; Carbon monoxide accumulation risk
Recalls/TSBs owners mention: Recall 16055 was performed. The reprogramming changed engine-start settings without owner notification.
Synthesized from 19 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
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…
EGR valve has failed leaving me stranded on side of the road. Problem was confirmed by a Chevrolet dealership. Engine light came on moments before it happened.
I have a engine code P0401
I had BECM failure and the car suddenly stopped in the middle of the road. They need to make this a safety recall.
Had engine trouble with your 2016 Chevrolet Volt?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2016 Chevrolet Volt?
It's a documented issue but not catastrophic. 19 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Based on the 19 complaints filed, engine issues most often appear around 7,400 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2016/Chevrolet/Volt.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.