There's a lot of information I could share about this. But I do want to remain semi-private, so I'll try to stick to the highlights and answer questions as needed. Instead of stating hard numbers, I'll compare against the value of my car according to Kelly Blue Book.

I'm reaching out here because I'm not a "car person" and I haven't gone through anything like this before. I figured if there's any other angles or strategies I'm missing then you all will probably fill in my blind spots. I want this to be over ASAP, but I also don't want to pay for the damage they've caused since it's thousands of dollars.

What happened:

• In May my car started having acceleration issues. I brought it in for repair at a dealership I've gone to for 2 years who has an in-house service department. The dealership's name includes the name of my car's manufacturer, so they're a specialized licensed dealer.
• At first they thought my catalytic converter was the issue, so they ran a bunch of tests. After extensive troubleshooting, they ended up taking it off and confirmed there was no damage or clogs. I received written updates, so this is well-documented.
• There is a known defect with engines in cars like mine. Therefore they put in a request for a free engine replacement, which was approved. They also reexamined my car after the approval was granted and recommended replacing another part at the same time. I approved and paid for that myself.
• When they gave me back my car, it was making a lot of weird sounds. I commented on it during pickup, and they told me not to drive too fast. Turns out it wasn't able to go on the highway at all and the check engine light quickly came on. I notified them and they asked me to return it. I put 100 miles on it during that period. For reference, driving on a highway has never been an issue for me.
• Upon examination, they informed me my catalytic converter was fully clogged and that it needed to be replaced. The sent me a quote for half the value of my car, a major expense.
• At first they tried arguing that it passed their test drive. But after I pointed out that I only drove 100 miles, they said it must have been clogged the whole time and they missed it repeatedly. They also said the new engine could in theory cause the issue, but stopped short of recommending it be replaced yet again. They also told me I could take my car somewhere else to get the repair done for cheaper. I have this conversation recorded.
• So I haven't had a working car for 100+ days now. It's still at the dealership and they've been trying to pressure me into taking it away, even though it's not save to drive and driving it could cause more damage.
• I've asked for a loaner vehicle repeatedly, and I'm always told none are available and that I'm on the wait list.

Here's what I've done so far.

• I have a support case with the manufacturer's national customer support system. I don't have my case managers direct line, but I call the regular line every day asking for updates. I also ask for it to be escalated and expedited. Sometimes the person tries to go above and beyond to give me the latest updates, but ultimately I don't think this is helping much. A request for a "good will" repair has been submitted and is awaiting review. Both my case manager and the dealership have told me it can take months to be reviewed. The person reviewing it is a regional manager. I've asked for their contact information but so far they've refused to disclose that.
• I've spoken to a lawyer briefly. They seemed to think it wouldn't be worth hiring them for this. They advised filing a claim against the dealership's insurer. As a backup, file a claim with my insurer and have them go after the dealership's insurer to cover the cost. I'm nervous about going this route because if they're not able to recoup then that claim would stay on my record which does have financial implications.
• I've asked the dealership directly for their insurance to file a claim. They refused to give it to me, saying only they file claims against their insurance. I don't know how else to try extracting this information. Cold calling as a prospective customer? Is it hanging on one of their walls maybe?
• I've spoken with the dealership's manager who oversees used cars. They made me an insultingly low offer yesterday, about 10% of its value. For reference, my car is less than 10 years old. Part of the reason it's so low is because they're budgeting in the repair. The manager doesn't seem to care that they damaged my car. But it does seem like they want the car off the lot, so maybe if I hold the line on this front the offer will increase. Unless they tow it, which I do slightly fear.
• I made some phone calls to governmental entities in my state. I've narrowed in on one entity that I'm told should have records of the dealership's insurance and also allow me to file a complaint. I got a voicemail today, but fingers crossed I can connect with them tomorrow.
• I sent an email to an executive last week. If I don't hear back I plan on doing this weekly with different executives. I'll add the names of each executive I've contacted to the bottom so the person has that additional context.
• I've reached out a local TV station who investigates things in the community. If I don't hear back I plan on contacting another one next week. I live in big city so I'm not confident this avenue will be fruitful.
• I've looked briefly into small claims court, but even a positive outcome requires me to collect. So that doesn't seem particularly helpful.
• I've looked briefly into leaving a BBB review, but I'm not sure that will accomplish much.

EDIT: See final update here

...and I'm a little worried the dealership might try to screw me over.

Some backstory:

In 2021, Chevrolet announced the Bolt EUV -- a slightly larger version of their Bolt EV.

Right after it got introduced, all Bolt EVs and EUVs underwent a battery recall. Dealers were unable to sell these until their batteries were replaced, despite the high demand for the vehicle.

In June 2022, Chevrolet announced a $6,300 price drop for the EV/EUV.

My current car was due for replacement (it's a 2003, lol); I wanted my next car to be an EV; the price drop made this something I could really afford; and it turns out that the EUV is literally the only electric vehicle at that price point that I can actually fit in (my head hits the ceiling in a Kona, for example).

In June 2022, I attempted to buy an EUV, only to find out that there were waitlists everywhere because the price drop increased demand, while the recall decreased supply. As such, I put in an order for a 2023 EUV with a deposit.

2023s went into production in July, but it turns out they're not made in order (which makes sense: the factory makes batches of similar types) and it also turns out that different dealerships have different "allocations" which means that they only get so many of a certain type of car -- even if it's been directly ordered by a customer.

I didn't know this at the time of ordering, but, the dealership I went with had a very low allocation for EUVs.

I have waited this entire time (which is not uncommon), and my car has finally arrived at the dealership. I'm slated to pick it up tomorrow and finish the purchase.

My concerns:

The dealership knows right now that they have me over a barrel. I've waited eight months for this thing. There is no other available inventory anywhere, as the EUVs sell immediately or, in most cases, are already spoken for before they arrive due to waitlists. People trying to get them complain about huge markups because of this.

I have a "motor vehicle purchase agreement" from the dealership from when I ordered the vehicle and made my initial deposit. That paper shows that I'll be paying MSRP for the vehicle, which I'm happy to do.

My question is: is the dealership going to try and make me pay something different, knowing that I'm not going to walk away from this? I feel somewhat comfortable that I have an agreement for the MSRP in black and white, but is that enough?

My other question is: is there some other way they're going to try to get one over on me? Something more subtle or that I don't expect? The last time I bought a car was ~15 years ago, and I pretty much stood there while my dad did the talking (also the car was used and super cheap).

I will be financing a loan through the dealership to pay for the car.

Basically, what can I do to make sure tomorrow goes as smoothly as possible? I'm hoping that it's easy, cut and dry, and there's no funny business, but I've also heard some horror stories -- especially from people trying to buy the particular car I'm getting.