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Discussion Starter · #1 · (Edited by Moderator)
Timeline from the following:

2020-2022 Chevrolet Bolt EV and EUV Defect Notice 573 Report for 21V650000

Sean Graham's Electrek article:
Everything we know about the Chevy Bolt EV fires
Summarized in table form
MY 2022 fires: 0
MY 2021 fires: 0
MY 2020 fires: 1
MY 2019 fires: 12 (10 or 11 Korea-made battery, 1 or 2 US-made battery)
MY 2018 fires: 1
MY 2017 fires: 5

TLDR Recall summary:
  1. First fire recall. Announced November 13, 2020. NHTSA 20V701000, GM N202311730 and N202311731. Covered 2017-2018 cars and 2019 cars with Korea-made batteries. Interim remedy of November 17, 2020 limited charging to 94%. Final remedy of April 29, 2021 (2019 cars) or May 26, 2021 (2017-2018 cars) was for cell voltage inspection, replacement of cells with voltage 0.08V lower than average, and installation of software with extra diagnostics and horn fire alarm. The final remedy procedure was also made available for then-non-recalled 2019 cars (campaign numbered GM N202323690).

  2. Second fire recall. Announced July 23, 2021. NHTSA 21V560000, GM N212343880 and N212343881. Initially covered 2017-2018 cars and 2019 cars with Korea-made batteries. Extended to cover all 2019 cars on August 20, 2021. Interim procedure is to set target charge to 90% or hilltop reserve mode, and perform the first fire recall final remedy if not already done. Final remedy will be replacing all battery modules with new ones (also resulting in 8% increase in capacity). Time frame is unknown, but will be done in stages, with groups of customers being invited to get the remedy based on GM's assessment of fire risk of their cars.

  3. Extended second fire recall. Announced August 20, 2021. NHTSA 21V650000, GM N212345940. Covers 2020-2022 cars. Interim procedure is to set target charge to 90%. Final remedy will be replacing defective battery modules. Time frame is unknown.
Historical updates:
  • March 17, 2019 to October 21, 2020: Fires (12 or 13) reported that are verified or suspected to be battery-caused (model years: 6 or 7 in 2019 cars, 1 in a 2018 car, 3 in 2017 cars, 1 either 2018 or 2017 Ampera-e, 1 unknown to the public model year). Some (5 at the time the first fire recall was announced) of them were verified by GM as having battery-caused fires. GM had information about the state-of-charge of some (4) of them; all were at high states-of-charge.

  • November 13, 2020: First fire recall announced (NHTSA 20V701000, GM N202311730 and N202311731). Recall applies to all 2017 and 2018 cars, and 2019 cars with Korea-made batteries (some 2019 cars have US-made batteries and were not recalled -- no fires occurred in cars with US-made batteries). GM issues stop-sale order to GM dealers (with financing compensation to dealers). Stop-sale for a given car lasts until the final recall procedure is completed and software installed.
  • November 17, 2020: Interim software available to limit charging to 94% (as displayed). Advisory to use hilltop reserve or target charge to 90% or lower before interim software is installed. Advisory to park outside if not limiting charging. Stop-sale still applies to cars at GM dealers which have had the interim software installed.

  • April 29, 2021: "Final" recall procedure and software available for 2019 cars (GM N202311731). The same procedure and software is also offered at no charge for non-recalled 2019 cars (GM N202323690).

  • May 1, 2021: Fire (1) reported in a 2019 car with interim software. Car had a history of frequent deep discharging.
  • May 26, 2021: "Final" recall procedure and software available for 2017 and 2018 cars (GM N202311730).

  • July 1, 2021 and July 2, 2021: Fires (2) reported in 2019 cars with final recall procedure completed and software installed (GM says that it became aware of these fires on July 2, 2021 and July 13, 2021). One car was verified by GM as having a battery-caused fire, while the other was not available for inspection. Both of these cars reported as having a history of frequent deep discharging.
  • July 14, 2021: Advisory to park outside and avoid charging unattended.
  • July 17, 2021: GM decides to have the second fire recall (which was announced on July 23, 2021).
  • July 19, 2021: GM reports that 18,823 (about 37%) of the 50,932 cars subject to the first fire recall have gotten that recall's final procedure and software. GM reports that 3 owners were unreachable, and 14 cars were removed as scrapped, stolen, or exported.
  • July 21, 2021: GM and LG identify the root cause of the fires.
  • July 23, 2021: Second fire recall announced (NHTSA 21V560000, GM N212343880). Additional advisory (in addition to previous advisory to park outside and avoid charging unattended) to use hilltop reserve or target charge to 90% or lower, and avoid going below 70 miles of remaining range (about 29% if based on EPA range of 238 miles).
  • July 25, 2021: Fires (2) reported. Both cars were 2019 model year, according to partial VINs shown. One fire occurred while charging (presumably L1 or L2 since it was at a home). The horn honking was heard, suggesting that the latest software for the first fire recall was installed. There are no details on state-of-charge or charging history. The other fire occurred while driving. There are no details on state-of-charge or charging history. However, this car had a US-made battery. This is probably the car described in recall documentation with the following: "On July 26, 2021, GM became aware, through its Customer Assistance Center, of an alleged battery fire in a vehicle outside of the recall population. GM conducted an inspection on this vehicle on August 6, 2021. Based on the physical evidence, GM determined that the probable origin of the fire was the vehicle’s high-voltage battery pack, and GM shipped the vehicle’s Hybrid Propulsion Control Module 2 (HPCM2) to its Milford Proving Grounds for further analysis."
  • July 26, 2021: Some customers receive email from GM describing the second fire recall and advisories.
  • July 2021: GM dealer service departments are notified to set hilltop reserve mode (2017, 2018) or target charge 90% (2019) as an interim recall service procedure for cars coming in for service (0.2 hours labor). This procedure must also be applied to cars in GM dealer inventory, which are also subject to a stop-sale order.
  • July 30, 2021: GM informs dealers that "Bolt EV & Bolt EUV lithium ion batteries for all model years for service are temporarily on hold."

  • August 3 and 12, 2021: According to recall documentation, "LG provided GM with updated teardown data and analysis indicating that both defects could be present in cells installed into vehicles outside of the original recall population."
  • August 4, 2021: GM 10-Q quarterly financial report states that GM "recorded a warranty accrual of $812 million" for the costs of the second fire recall. It also notes that the cost of the (diagnostic and software) remedy for the first fire recall was "not material".
  • August 6, 2021: GM inspects a car that caught fire on July 25, 2021. GM informs GM dealers of a Working Capital Assistance Program (basically a financing subsidy) for recalled cars which are under a stop-sale order.
  • August 9, 2021: LG revises second quarter operating profit from KRW 1.11 trillion (USD $992.08 million at the time of the original report) to KRW 878 billion (USD $763.56 million at the time of the revision) for Bolt recall costs. Difference is about KRW 232 billion (USD $201 million at the time of revision). The converted-to-USD amounts are subject to exchange rate fluctuations.
  • August 13, 2021: Dealers received advisory bulletin to expect "Advisory" and "Remedy" letters to be sent to Bolt owners "late this month". Some recalled cars are marked as high priority based on manufacturing records and will be moved from GM recall number N212343880 to N212343881. Customers with these cars will receive the "Remedy" letter and can begin scheduling appointments on or after August 23, 2021 for service on August 30, 2021 or after. Other customers will receive the "Advisory" letter stating that parts are not yet available. Both letters continue to state that customers should continue to limit charging to 90% or hilltop reserve, avoid discharging below 70 miles or remaining range, and park outside until the remedy is done. See attached PDFs.
  • August 16, 2021: Fire (1) reported. Car was 2020 model year. Car was charged to 100% and was parked (still plugged in) for about 14 hours before it caught fire. Car had about 6,000 miles and was commonly discharged to about 30% before being recharged. According to recall documentation, "after GM’s safety engineering team conducted a detailed analysis of this new data, GM’s Safety and Field Action Decision Authority decided to expand NHTSA recall 21V560 to include all 2019 model year Chevrolet Bolt EV vehicles not covered by the prior recall, plus all 2020 – 2022 model year Chevrolet Bolt EV vehicles and all 2022 model year Chevrolet Bolt EUV vehicles." This recall was announced on August 20, 2021.
  • August 18, 2021: Some customers get "Remedy" (or "881") letters (they can make appointments starting August 23, 2021 for repair starting August 30, 2021) or "Advisory" (or "880") letters (parts are not available yet for their cars). See attached PDFs for the letter templates. In addition, those receiving "Advisory" letters have reported receiving additional letters saying that lithium-ion battery modules will (eventually) be replaced by "all-new lithium-ion battery modules" providing "8% additional battery capacity" with a "new 8-year/100,000 mile Limited Parts Warranty for your lithium-ion battery upon completion of the battery module replacement".
  • August 20, 2021: General Motors on Friday said it is expanding its recent recall of Chevrolet Bolt EVs to newer models (through 2022) of the electric car due to potential fire risks. The recall expansion is expected to cost the automaker an additional $1 billion, bringing the recall’s total to $1.8 billion to replace potentially defective battery modules in the vehicles. The GM press release identifies specific defects as a "torn anode tab" and a "folded separator." 2019 cars not previously included in the existing recall numbered NHTSA 21V560000 / GM N212343880 have been added to to that recall. The recall numbers for 2020-2022 cars are NHTSA 21V650000 / GM N212345940.
  • August 20, 2021: GM announces that Bolt production will pause starting August 23, 2021, intending to resume August 30, 2021. The stated reason is the chip shortage.
  • August 23, 2021: A customer who received the "Remedy" (or "881") letter reported calling a dealer who then informed them that parts will be delayed until early September.
  • August 30, 2021: Fire (1) reported. Car was 2017 model year "after getting recalls done". Was parked and not charging with 34 miles of estimated remaining range (about 14% state-of-charge by EPA mileage) at the time of the fire. Charged only occasionally, usually to "about 85%" at a level 2 station at work.
  • August 30, 2021: GM announces that Bolt production will remain paused until "LG can supply defect-free battery cells".

  • September 2, 2021: GM announces that most other North American factories will shut down (or extend existing shutdowns) due to the chip shortage. Some intend to resume September 13, 2021 or September 20, 2021.
  • September 6, 2021: Planned 2017-2019 owner interim notification date. The letters received by customers around August 18, 2021 may be these planned notifications sent ahead of the original schedule.
  • September 8, 2021: Owners of 2020-22 Bolts receive an email notification about the recall, providing charging / parking guidance, module replacement, and warranty extension. Note that target date for owner notification was/is October 4.
  • September 9, 2021: Bolt production reported to remain suspended until at least September 24, 2021, pending decisions by GM and LG on how to produce batteries without the recall defects.
  • September 13, 2021: Fire reported in Cherokee County, Georgia, MY 2019. No other details available yet.
  • September 16, 2021: GM says that the Orion plant that makes Bolts will remain shut down until at least October 15, 2021.
Future estimated or planned events:
  • October 4, 2021: Planned 2020-2022 owner interim notification date. The letters received by customers around September 8, 2021 may be these planned notifications sent ahead of the original schedule.

  • Unspecified: GM will provide estimated mailing dates for the final remedy when available.
 

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I got a request from MichBolt but unfortunately my bandwidth (time) is limited. Here are some useful mostly NHTSA URLs. I may refine this later when I find time.


All of these NHTSA URLs come from associated documents for campaigns 20V701000 (initial battery fire recall announced 11/30/20) and 21V560000 (announced 7/23/21, after some fire(s) on Bolts w/"final remedy" applied). 20V701000 currently has 37 docs and I think it's pointless for me to post all of them and attempt to describe them all. Some are outdated or superseded anyway or just not very relevant now.

I've included ones I think are most relevant at this point.

20V701000: initial battery fire recall from 11/13/20
Defect notice 573 report (dated 11/13/20) for 20V701000 https://static.nhtsa.gov/odi/rcl/2020/RCLRPT-20V701-2513.PDF
Interim patch procedure: https://static.nhtsa.gov/odi/rcl/2020/RCSB-20V701-2489.pdf - it is one of many that refers to a stop sale and that applying this interim charge % limiter patch was NOT sufficient to allow a GM dealer to sell the car.

Recall 573 doc from 4/29/21: https://static.nhtsa.gov/odi/rcl/2020/RCLRPT-20V701-7407.PDF
"Final" remedy that came out May 2021 to cover 2017 to 2019 recalled Bolts: https://static.nhtsa.gov/odi/rcl/2020/RCSB-20V701-3618.pdf. A version covering only recalled '19 Bolts came out first but is basically the same.
FAQ for above "final remedy": https://static.nhtsa.gov/odi/rcl/2020/RMISC-20V701-9809.pdf
Background/extra info on "final" remedy: Bolt EV Battery Cell Inspection – TechLink

Quarterly report (as of 7/21/21) on how many received the "final remedy": https://static.nhtsa.gov/odi/rcl/2020/RCLQRT-20V701-6948.PDF

21V560000: above population of vehicles recalled again on 7/23/2021
Defect notice 573 report for 21V560000 (dated 7/23/21): https://static.nhtsa.gov/odi/rcl/2021/RCLRPT-21V560-6162.PDF

Do note that the 573 reports do have Component Part Numbers. Recalled Bolts (all '17 and '18 + subset of '19) should have a battery part # visible on the casing from the driver's side that matches one of those part numbers.

7/31: two new documents:

https://static.nhtsa.gov/odi/rcl/2021/RCSB-21V560-6354.pdf
https://static.nhtsa.gov/odi/rcl/2020/RCSB-20V701-6348.pdf

2020 to 2022 Bolt EV and EUV bulletin and FAQ:
Expansion of recall to include 2020 to 2022 Bolt EV and EUV https://static.nhtsa.gov/odi/rcl/2021/RCLRPT-21V650-2919.PDF
Bulletin https://static.nhtsa.gov/odi/rcl/2021/RCSB-21V650-4012.pdf
FAQ: https://static.nhtsa.gov/odi/rcl/2021/RMISC-21V650-3363.pdf

2017 to 2019 Bolt FAQ from Aug 2021: https://static.nhtsa.gov/odi/rcl/2021/RMISC-21V560-8422.pdf
Expansion of recall to include rest of 2019 Bolts: https://static.nhtsa.gov/odi/rcl/2021/RCLRPT-21V560-5475.PDF
Letter being sent to 2017 to 2019 owners about replacement of all modules, increased capacity and new battery parts warranty: https://static.nhtsa.gov/odi/rcl/2021/RMISC-21V560-4200.pdf

N212343880 Chronology of Defect / Noncompliance Determination
573.6 (c) (6) (7) Describe the chronology of events leading up to the defect decision or test data for the noncompliance decision:" from Aug 20, 2021: https://static.nhtsa.gov/odi/rcl/2021/RMISC-21V560-8766.pdf

If the mods wish to edit or re-organize my post, go ahead. Hopefully, the above is all accurate.
 
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