GM issues a second recall of Chevy Bolt EVs after vehicles catch fire

July 26, 2021: -General Motors is issuing a second recall of its 2017-2019 Chevrolet Bolt EVs after at least two of the electric vehicles that were repaired for a previous problem erupted into flames.

On Friday, the automaker said that officials with GM and LG Energy Solution, which supplies the battery cells of vehicles, have identified a second “rare manufacturing defect” in the EVs that increases fire risk. The recall covers about 69,000 cars globally, including nearly 51,000 in the U.S.

To fix the problem, GM said it would replace defective battery modules in the vehicles, which can be costly but will be accessible to owners. The automaker says the repair is different than the previous fix, which primarily relied on software and, in few cases, replacement modules.

“We’re working with our supplier and manufacturing teams to determine how best to expedite battery capacity for module replacement under the recall,” GM spokesman Dan Flores said in an email.  “These teams are working around the clock on this issue.”

The company “will notify customers when replacement parts are ready,” Flores said.

In the meantime, GM asks impacted Bolt EV owners to set their vehicles to a 90% state of charge limitation uses Hilltop Reserve mode or Target Charge Level mode.

GM also is asking owners to avoid depleting their battery below approximately 70 miles remaining range and, as advised in the previous week, continue not to park their vehicles charge them unattended overnight “out of an abundance of caution.”

In November, the first recall of the Bolt EVs due to fires was announced by GM and the National Highway Traffic Safety Administration. The automaker rolled out what it believed was a permanent fix for the problem this year.

One of the recent fires occurred instead; the vehicle was charging at the home of a Vermont state lawmaker this month. The other fire happened in New Jersey.

Last week, the NHTSA said battery cell packs in the impacted vehicles have the potential to smoke and internally, which could spread to the rest of the car and cause a structure fire if the car is parked inside a garage or near a house.

GM has repurchased some of the recalled vehicles, but the company has declined to say how many. Automakers often buy back vehicles to appease unhappy customers and triggering state lemon laws and litigation.