this post was submitted on 18 Oct 2024
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The Volt is a hybrid gas & electric. The gas engine is there in part to charge the battery, and in part to power the electric drivetrain.
Under normal drive conditions, the gas engine short-cycles and doesn't really come up to operating temp, which gums up the EGR valve causing the valve to pull too much current and start blowing fuses that power other critical parts of the battery charge control circuit. Left us stranded on an interstate this past spring until I could limp it to an auto parts store off the next exit to buy a replacement fuse. It ate two more before we could get home.
(edit: the OEM part is no longer manufactured, and what OEM stock is left is unobtainable. What's left is remanufactured, Chinese aftermarket, or a scam. Install at your own peril.)
The workarounds to disable or bypass the EGR (for now) can cause other potential issues with the engine in the long run. Simply disconnecting the EGR keeps it from blowing fuses, but then the car isn't road legal in many states because it fails emissions. Also, the EGR is part of the combustion engine's cooling system, so not recirculating hot crank case gases works the rest of the cooling system harder, and potentially damages the pistons & cylinders.
The whole situation is a mess. Thankfully we have a second vehicle that's a regular gas engine, so we use that one for distance driving, and can just use this one for around-town driving while we figure out what to do next with it.