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GM Recalling Another 2.7 Million Vehicles In Five Separate Campaigns

The recalls keep rolling in from General Motors, evidently keen to avoid repeating the mistakes of the ignition-switch debacle and clean house. This time they're all coming at once, with five separate recalls announced together covering approximately 2.7 million vehicles. The largest of the five actions involves over 2.4 million units of the previous-generation Chevrolet Malibu and Malibu Maxx, Pontiac G6 and Saturn Aura in order to fix brake light wiring harness, which have been found to be susceptible to corrosion. The recall is separate from the 56k Aura sedans which GM recently recalled over faulty shift cables, not to mention the previous massive recall of 1.3 million vehicles – some of them the same models – but appears to have resulted from the National Highway Traffic Safety Administration investigation that started with the G6 almost a year ago. The second-largest campaign involves the 2014 Chevy Malibu, specifically those fitted with GM's 2.5-liter engine and stop/start system, approximately 140,000 examples of which has been found to have problematic brakes. The issue does not appear to be connected to the recall of 8k Malibu and Buick LaCrosse sedans (also involving brake woes) which we reported upon last week. Four crashes have been reported in such models, but GM admits it's not yet clear if the problem was a contributing factor in the accidents. A further 112k Corvette models from the 2005-2007 model years are being called in for problems with their low-beam headlamps resulting from a flexing relay control circuit wire that's not meant to bend. GM says it is "aware of several hundred complaints" about this issue, but notes that there have been no reports of related accidents. In addition, over 19k examples of Cadillac CTS from the 2013 and 2014 model years are being recalled over windshield wipers that might not work after a jump start. Finally, GM is also bringing in 477 examples of its 2014 Chevy Silverado, Tahoe and GMC Sierra (though not the Yukon) to fix a problem with a tie rod in its steering rack. As ever, all recall repairs will be performed free of charge, and GM is now estimating that recall-related actions this quarter will result in an estimated $200-million charge against its second-quarter earnings. Read the full announcement from GM below for further details.

Chevy Volt owners log half a billion electric miles, 2015 production starts

As General Motors gets ready to start 2015 Volt production Monday, Chevrolet is looking back at some of the numbers that got the car to where it is today. The headline number is that Volt owners have collectively put more than a half-billion electric miles on their cars. The unsurprising upshot is that, if you went out and bought a Volt, you're pretty keen on getting as many electric miles out of it as possible. 90 percent of all Volt trips are done purely on electric power. The typical Volt driver goes 970 miles between fill-ups, GM says, and that means that 63 percent of all miles are done on battery power. General Motors executive director Larry Nitz gave AutoblogGreen a few more details on the usage habits of Volt drivers, including that 81 percent of commuting miles are electric. Two-thirds of US Volt drivers charge their vehicle 1.4 times a day, a clear indicator of drivers trying to maximize electric miles through opportunity charging. In fact, Nitz said, 90 percent of all Volt trips are done purely on electric power. GM also says that the Volt's official 35 miles of electric range is still doable for many owners who have had their car for more than 30 months. Looking ahead, we know that one upgrade for the 2015 Volt will be 4G LTE connectivity that can turn the car, like others in the GM family, into a mobile wifi hotspot. We're of course much more interested in when GM is finally going to start production of the next-gen Volt, but GM officials would only tell us that they're very excited about the still-secret vehicle, promising we'll be learning more "soon." Nitz did confirm that today's Volt drivers are most interested in three things from the next-gen model: more range, a lower price and a fifth seat. He did not say whether or not GM will be able to deliver on those requests. Chevrolet Volt Owners Surpass Half a Billion Electric Miles After 30 months of use, a sampling of Volts shows consistent all-electric range 2014-06-19 DETROIT – Since its launch in late 2010, Chevrolet Volt owners have accumulated more than half a billion all-electric miles. Additionally, based on a General Motors' study of more than 300 Volts in service in California for more than 30 months, many owners are exceeding the EPA-rated label of 35 miles of EV range per full charge, with about 15 percent surpassing 40 miles of range.

How GM engineers are using diaper 'snow' to keep you warm

Testing how snow affects General Motors' vehicles isn't really a problem right now for the company's engineers, but in the dog days of summer the process isn't exactly easy. The only real option is for them to book time at the automaker's climatic wind tunnel. However, a flash of brilliance from an engineer allows snow to be simulated regardless of the temperature outside, and the discovery is all because of his daughter's wet diaper. The realization came to GM Thermal Systems engineer Nicholas Jahn while he was swimming with his daughter and noticed how her diaper ballooned in size in the water. He found out the substance that makes this possible is called sodium polyacrylate. When the material gets wet it grows and forms fluffy flakes that are a close imitation of snow. Best of all, the stuff can be prepared easily any time of the year, and it's reusable. The engineering team uses the material to test the effectiveness of the heating systems of GM's vehicles. They spread the sodium polyacrylate over the inlets at the base of the windshield to obstruct the airflow and then crank the heater. After some time, they can see how much is being sucked into the system and design more efficient systems in the future. See how the process works in the video above and read about the diaper discovery in GM's press release below. Diapers Change Chevy Cruze Winter Warm-up Time GM validation engineer uses diaper material "snow" to reduce frigid drives 2015-01-06 DETROIT – An item commonly found on an infant's changing table is helping General Motors' engineers simulate snow year round, ensuring heating systems in cars like the 2015 Chevrolet Cruze can quickly and efficiently warm its interior. Packed snow can prevent air from entering the inlet panel at the bottom of the windshield, obstructing the flow of air into the heating system and reducing the amount of air it can push out. This can lead to less efficient warming of the car's interior and windshield defrosting. "The last thing anyone wants to do when it's freezing cold out is scrape their windshield," said Nicholas Jahn, GM Vehicle Thermal Systems engineer. "The testing we perform on the Chevrolet Cruze with the diaper material allows us to maximize the car's heating capabilities." Ironically, Jahn stumbled upon his diaper-based testing method in the middle of summer. During a swim with his daughter, he noticed her diaper multiplied in size when it came into contact with water.