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GM to replace battery modules in recalled Chevy Bolt EVs starting next month

General Motors said Monday it will replace battery modules in recalled Chevrolet Bolt EV and Bolt EUV vehicles as soon as next month now that supplier LG Chem has restarted production of cells at two Michigan factories.

Replacement modules, which are made up of lithium-ion battery cells, will begin shipping to dealers as soon as mid-October, the company said. Chevy Bolt EV owners will be able to bring their vehicles to the dealership, where the old modules will be swapped out for new ones.

GM halted production of Chevy Bolt EV and EUVs in August due to a battery pack shortage related to the widespread safety recall of the two electric vehicles. The production downtime has been extended twice since then. Battery packs in EVs are comprised of modules.

The recall, which includes all Chevy Bolt EV and EUV models made since 2017, was issued after the automaker discovered two manufacturing defects in the battery cell — a torn anode tab and folded separator — that could increase the risk of fire. The fire risk prompted GM to recommend Bolt owners set the vehicle to a 90% state of charge limitation, avoid depleting the battery below 70 miles of range and charge the vehicle more frequently. GM still recommends owners park their Bolt EV and EUVs outside immediately after charging and to not leave vehicles charging indoors overnight.

LG has new manufacturing processes in place and has worked with GM to improve its quality assurance programs to provide confidence in its batteries moving forward. GM said the battery supplier will institute these new processes in other facilities that supply cells to the automaker.

Doug Parks, GM’s executive vice president of global product development, purchasing and supply chain, noted in a statement that resuming battery module production is a first step. However, GM’s Chevy Bolt EV problem is not entirely solved. The company must complete the replacement process for all recalled Bolts and assuage owners that the vehicles are safe to charge and park.

GM is counting on new advanced diagnostic software package to help. The company said it will launch the software package, which will need to be installed by dealers, in the next 60 days. The diagnostic software is designed to detect specific abnormalities that might indicate a damaged battery in Bolt EVs and EUVs by monitoring the battery performance.

The software will alert customers of any anomalies, according to GM, which said customers will be able to return to a 100 percent state of charge once all diagnostic processes are complete.

GM, which aims to add 30 new EVs to its global lineup by 2030, also must secure the battery cells it needs to power these vehicles. LG is its primary and longtime partner in this endeavor. Parks said GM will “continue to work aggressively with LG to obtain additional battery supply.

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