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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.

GM will likely build PHEV batteries in China soon

It's a big week for batteries. Friday, Tesla will hold a big event at its Gigafactory in Reno, NV. But even in Michigan, there are things happening on the electrified automotive front. This was proven when GM invited journalists to its Brownstown Battery Assembly Plant today, highlighting the six different battery packs it makes for nine vehicles around the world (plus a tenth, coming to Asia, that has not yet been announced). During our tour, we learned a few interesting tidbits that we thought readers would like to hear: The Cadillac CT6 plug-in hybrid launches in China this fall before coming to the US next year. GM builds the battery packs in Michigan and ships them to China for final assembly in the PHEV. For now, this is all fine for GM to qualify for China's incentives for building green cars in the country. But, as Bill Wallace, GM's director of global battery systems, told AutoblogGreen, this could change thanks to the country's 'Made in China 2025' plan. The situation is "evolving," he said, and it's a safe assumption that GM will need to build packs in China some day. For the CT6 PHEVs that will be sold in the US, the batteries will make a round trip, since GM will only build the plug-in version in China. As for the range of the CT6 PHEV, that hasn't been announced, but since China offers incentives for vehicles that get at least 50 kilometers (31 miles), that's a likely target (the US range (UPDATE: GM did announce an expected range for the CT6 PHEV in the US at the LA Auto Show last fall, saying it would "travel approximately 30 miles on a full electric charge"). The battery pack in the CT6 is also a clunky box-type thing, totally unlike the near-elegant T-shape used in the Volt. This despite the fact that the guts of the two packs are similar. Both have 192 li-ion cells and weigh almost the same, but GM tuned the CT6 pack for acceleration instead of range, the way it did with the Volt's pack. Still, the main reason the packs are different is because the CT6 is a rear-wheel drive vehicle, and the tunnel that the Volt's pack uses is occupied by the driveshaft. Despite the highly touted second-gen Chevy Volt going on sale last year, GM still has the capacity to build battery packs for the old, first-gen model. This is because the company is legally required to be able to provide replacement packs for warrantied vehicles (for up to 10 years), and the second-gen packs don't fit into the first-gen vehicles.

Why GM will import the Cadillac CT6 PHEV from China

There's a clear-cut reason that General Motors is going to build its upcoming plug-in hybrid CT6 sedan in China. Sure, the car will be sold in China and the US, but the real reason for the "Made In China" stamp is environmental. If an automaker wants to build a new model in China, adding a green powertrain is an easy way to do that. The CT6 will have both a PHEV option as well as standard gas engine versions. David Leone, Cadillac's executive chief engineer, told AutoblogGreen recently that, "[China is] far more receptive to approving localized production of vehicle programs that have new energy vehicle powertrain applications." To put it succinctly, since the CT6 has a PHEV option, it is easier for GM to build all CT6 models in China. Some of them will then be imported to the US. "Most new global Cadillacs will also be produced in China as well. It's our second-largest market in the world." "To bring any new car into China, to produce it, you need government approval," Leone said. "The government isn't interested in bringing many new cars to market that don't have new energy credits. [The CT6] also provides new energy credits that enables it to be an attractive, well-received product in China." Leone said that there are two main markets for the various CT6 models: China and the US. The car will arrive in the 2017 model year, so some time after the end of June 2016. There are other practical reasons to build the PHEV in China, like the cells in the battery pack. Those are provided by LG Chem, which makes some cells in Michigan but more in South Korea. And GM already builds cars in China through its joint venture with SAIC, Shanghai General Motors, or SGM. "In February 2013 we started making the XTS, in summer of 2014 we started making the ATS-L," Leone said. "We will be producing [the CT6] within a number of months. Most new global Cadillacs will also be produced in China as well. It's our second-largest market in the world." The Chinese and US versions of the CT6 will be identical, Leone said. While some Cadillacs sold in China are slightly different than the US versions – the Chinese ATS is 77 millimeters longer, for example – the CTS6 PHEV will be exactly the same in both places, other than slight tweaks to the trim levels. Still, "more of our cars going forward will be the exact same car," he said. That doesn't mean that sales will be the same everywhere.