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2013 Buick Regal

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2013 Buick Regal do not stand out strongly from the model-year median of 29.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

62 reports with mileage · 29 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Exterior Lighting. Review the 37 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 9 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

6 crash reports2 fire reports4 injury reports

What owners actually said

91 reports
81,290 miles · Sep 14, 2020
EnginePower TrainSteeringFire

TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE LOSS ACCELERATION, STEERING WHEEL BECAME DIFFICULT TO TURN. IN ANOTHER WHEN TURN OFF THE ENGINE, THE VEHICLE FAILED TO START. A WARNING LIGHT ILLUMINATED ROLL DRIVER SIDE WINDOW UP, THE TRUNK OPEN AND THE WINDSHIELD WIPER INDEPENDE…

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TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE LOSS ACCELERATION, STEERING WHEEL BECAME DIFFICULT TO TURN. IN ANOTHER WHEN TURN OFF THE ENGINE, THE VEHICLE FAILED TO START. A WARNING LIGHT ILLUMINATED ROLL DRIVER SIDE WINDOW UP, THE TRUNK OPEN AND THE WINDSHIELD WIPER INDEPENDENTLY START TO FUNCTION. THE VEHICLE WAS TOWED TO ED MARTIN BUICK GMC, 9896 N MICHIGAN RD, CARMEL, IN 46032, AND WAS DIAGNOSED THAT THE TIMING CHAIN DETACHED. THE VEHICLE WAS NOT REPAIR DUE TO THE REPAIR FEES. FIVE CODE ALSO CAME UP, P0131, P0016, P0017, P0014 AND P0171. AND LEAVING THE DEALER, THE VEHICLE FAILED TO START AND WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE TIMING CHAIN, BALANCE CHAFF, CHAIN KIT, TIMING COVER GASKET SET, CAM COVER GASKET SET AND TWO CAMSHAFT SENSORS, WERE REPLACED. THE WHILE LEAVING THE INDEPENDENT MECHANIC, THE VEHICLE LOSS ACCELERATION, HEAT BLOWING AT THE FLOW BOARD AN UNKNOWN ODOR ENTERED THE VEHICLE CABIN COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN BACK TO THE INDEPENDENT MECHANIC AND WAS INFORMED TO TAKE THE VEHICLE TO A BUICK DEALER. WHILE ON THE WAY TO THE DEALER, THE PARK TO DRIVE GEAR WAS CLUNKING AND JERKING FROM 3RD TO 2ND AND 4TH TO 3RD. THE VEHICLE WAS TAKEN SEVEN TIMES TO THE SAME DEALER. THE CONTACT MENTIONED THAT SHE TAKEN THE VEHICLE TO A TRANSMISSION SHOP BUT WAS UNABLE TO DETERMINE A FAILURE. ON ANOTHER OCCASION, THE VEHICLE LOSS ACCELERATION AND JERKING IN GEARS, HEAT ENTERING THE VEHICLE CABIN AND SQUEALING. NO CHECK ENGINE LIGHT ILLUMINATED AND THE BATTERY COVER WAS MELTED ON ONE SIDE. NO INDICATION ON THE OVERHEAT THAT LEVEL THE TEMPERATURE GAGE. THE FAILURE MILEAGE WAS APPROXIMATELY 81,290.

NHTSA ODI #11354914

Mileage unknown · Jul 24, 2020
Electrical System

I'M HAVING A PROBLEM WHERE MY CAR WON'T START AT TIME I HAVE PURCHASED A NEW BATTERY AND HAD THE ALTERNATOR CHECK ALL GOOD SOMETIMES I SMELL SOMETHING BURNING AND I NOTICE THERE'S A RECALL ON 2013 BUICK REGAL GS

NHTSA ODI #11341394

30,000 miles · Jul 13, 2020
Exterior Lighting

TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT HIS HEADLAMP HOUSINGS CONSTANTLY FILLED UP WITH CONDENSATION CAUSING THE BULBS TO FAIL PREMATURELY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE BALLASTS AND BULBS WERE REPLACED AND THE HEADLAMP HOUSINGS RESEALED. MCGUIRE BUICK GMC (1625 US-46, LITTLE…

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TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT HIS HEADLAMP HOUSINGS CONSTANTLY FILLED UP WITH CONDENSATION CAUSING THE BULBS TO FAIL PREMATURELY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE BALLASTS AND BULBS WERE REPLACED AND THE HEADLAMP HOUSINGS RESEALED. MCGUIRE BUICK GMC (1625 US-46, LITTLE FALLS, NJ 07424 (973)200-6699) WAS CONTACTED AND THE CONTACT WAS INFORMED THAT THE WARRANTY WAS EXPIRED. THE CONTACT WAS PROVIDED AN ESTIMATE OF $3,000 TO REPLACE THE HEADLAMPS. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 30,000.

NHTSA ODI #11338991

120,000 miles · Jun 19, 2020
Electrical SystemExterior LightingStructureCrash

I'VE HAD FOR THE LAST FEW YEARS HAD ISSUES WITH MY 2013 BUICK REGAL TURNING OFF WHILE DRIVING CAUSING A FEW ACCIDENTS THAT HAS NEARLY CAUSE ME MY LIFE. THE CAR HAS HAD MULTIPLE ELECTRICAL ISSUES I'VE TRIED GETTING FIXED AND I'VE DEALT WITH DAMAGE TO MY VEHICLE DUE TO THIS. CAR HAS TURNED OFF ON ME WHILE IN MOTION. I'VE REPLACED …

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I'VE HAD FOR THE LAST FEW YEARS HAD ISSUES WITH MY 2013 BUICK REGAL TURNING OFF WHILE DRIVING CAUSING A FEW ACCIDENTS THAT HAS NEARLY CAUSE ME MY LIFE. THE CAR HAS HAD MULTIPLE ELECTRICAL ISSUES I'VE TRIED GETTING FIXED AND I'VE DEALT WITH DAMAGE TO MY VEHICLE DUE TO THIS. CAR HAS TURNED OFF ON ME WHILE IN MOTION. I'VE REPLACED THE BATTERY AND I'VE SPENT SEVERAL 1,000S OF DOLLARS TRYING TO GET IT REPLACED. *TR

NHTSA ODI #11329679

Mileage unknown · Jun 12, 2020
Exterior Lighting

THE DRIVER'S SIDE HEADLIGHT HAS AN ISSUE WITH THE SEAL (NO VISIBLE CRACKS OR DAMAGE TO THE LIGHT) WHICH ALLOWS WATER/CONDENSATION TO ACCUMULATE IN THE HEADLIGHT. THIS ENDS UP BLOWING THE BULBS AND FUSE. EVEN AFTER REPLACING THE BULB AND THE FUSE, THE LIGHT STILL WILL NOT WORK. AFTER REPLACING THE FUSE, THE DAYTIME RUNNING LIGHTS…

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THE DRIVER'S SIDE HEADLIGHT HAS AN ISSUE WITH THE SEAL (NO VISIBLE CRACKS OR DAMAGE TO THE LIGHT) WHICH ALLOWS WATER/CONDENSATION TO ACCUMULATE IN THE HEADLIGHT. THIS ENDS UP BLOWING THE BULBS AND FUSE. EVEN AFTER REPLACING THE BULB AND THE FUSE, THE LIGHT STILL WILL NOT WORK. AFTER REPLACING THE FUSE, THE DAYTIME RUNNING LIGHTS NO LONGER WORK AND THERE IS APPARENTLY AN ELECTRICAL ISSUE WITH THE WIRING HARNESS THAT CAUSES A SHORT IN THE LIGHTING (SEE ATTACHED VIDEO). I WAS DRIVING AT NIGHT WHEN MY DRIVER'S SIDE HEADLIGHT COMPLETELY STOPPED WORKING. THERE IS NO INDICATION TO ALERT THE DRIVER WHEN THIS HAPPENS. I ONLY KNEW BECAUSE IT HAPPENED AT NIGHT AND DRASTICALLY DECREASED MY VISIBILITY (RURAL AREA WITH NO STREET LIGHTS). THIS IS OBVIOUSLY A HUGE SAFETY ISSUE. I'VE CONTACTED BUICK AND WAS TOLD THAT THERE IS NO RECALL AND THAT IT'S NOT COVERED DUE TO MY VEHICLE BEING OUTSIDE OF THE WARRANTY. THE ENTIRE HEADLIGHT ASSEMBLY NEEDS TO BE REPLACED AND IS APPROXIMATELY $1,500 TO REPLACE (NOT TO MENTION THE $100 BULB THAT I HAD JUST REPLACED THAT BLEW OUT). AFTER RESEARCHING THIS MATTER, IT APPEARS THAT THERE ARE MULTIPLE COMPLAINTS FOR THE 2013 YEAR MODEL WITH HID LIGHTS. THIS SEEMS TO BE A COMMON PROBLEM AND THERE SHOULD BE A RECALL FOR THIS. THIS VEHICLE FAILS TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." SOMETHING NEEDS TO BE DONE ABOUT THIS!!! THE MANUFACTURER WILL NOT CORRECT THIS ISSUE IF YOU ARE OUTSIDE OF THE WARRANTY UNLESS THEY ARE FORCED TO BY A RECALL. *TR

NHTSA ODI #11328578

117,000 miles · Jun 1, 2020
Electrical System

ELECTRICAL ISSUES, MASS AIRFLOW SENSOR REPLACED 3 TIMES HAS CONTINUED TO GO OUT, VEHICLE SHUTS DOWN WITH NO CODES AVAILABLE, VERY HAZARDOUS, VEHICLE WILL NOT START UNLESS YOU DISCONNECT THE NEGATIVE BATTERY TERMINAL AND RESET THE COMPUTER, AFTER THAT THE VEHICLE WILL RUN FOR A SHORT PERIOD OF TIME ADD WILL SHUT DOWN AGAIN. *TR

NHTSA ODI #11326757

11,700 miles · Jun 1, 2020
Electrical System

ON MY 2013 BUICK REGAL GS THE MASS AIR FLOW SENSOR HAS CONTINUED TO SHUT DOWN 3 TIMES AND HAS BEEN REPLACED 3 TIMES, THE CAR CONTINUES TO SHUT DOWN WITH NO GM CODES. PLEASE CONTACT ME ASAP OR I'LL HAVE NO CHOICE BUT TO CONTACT MY COUNSEL TO FILE A LEGAL COMPLAINT AGAINST GM FOR DANGEROUS CAR. *TR

NHTSA ODI #11326735

70,000 miles · Mar 11, 2020
Exterior Lighting

THE HID LIGHTING BURNED THROUGH THE PLASTIC CASE ALLOWING THE STRATEGICALLY PLACED BALLAST ON THE BOTTOM TO FILL WITH WATER AND THE LIGHT BULB FAILED TO IGNITE. A MAJOR SAFETY ISSUE WHILE DRIVING

NHTSA ODI #11317581

30,000 miles · Mar 9, 2020
Exterior Lighting

TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT THE DRIVER SIDE HEAD LIGHT FAILED TO OPERATE WITHOUT WARNING. THE CONTACT NOTICE THAT MOISTURE HAD ACCUMULATED INSIDE OF THE DRIVER'S SIDE HEADLAMP ASSEMBLY. THE CONTACT ALSO NOTICED THAT THE HEADLAMP CIRCUIT BOARD WAS CORRODED DUE TO THE CONDENSATION. THE MANUFACT…

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TL* THE CONTACT OWNS A 2013 BUICK REGAL. THE CONTACT STATED THAT THE DRIVER SIDE HEAD LIGHT FAILED TO OPERATE WITHOUT WARNING. THE CONTACT NOTICE THAT MOISTURE HAD ACCUMULATED INSIDE OF THE DRIVER'S SIDE HEADLAMP ASSEMBLY. THE CONTACT ALSO NOTICED THAT THE HEADLAMP CIRCUIT BOARD WAS CORRODED DUE TO THE CONDENSATION. THE MANUFACTURER WAS CONTACTED AND A CLAIM NUMBER WAS PROVIDED. THE VEHICLE WAS TAKEN TO PENSKE BUICK GMC OF CERRITOS LOCATED AT (18400 STUDEBAKER RD, CERRITOS, CA 90703). THE CONTACT WAS THEN NOTIFIED BY THE DEALER THAT THE REPAIR WAS NOT FREE AND WOULD HAVE TO BE PAID FOR OUT OF POCKET. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 30,000.

NHTSA ODI #11317114

46,000 miles · Feb 11, 2020
Exterior Lighting

DRIVER'S HEADLIGHT QUIT WORKING. TOOK IT TO DEALER, THEY SAID IT WAS THE HEADLIGHT. WASN 'T THE HEADLIGHT. SAID IT WAS THE BALLAST. WORKED FOR 2 MINUTES. THEY SAID THAT TICKET WAS CLOSED AND CHARGED ME $650. THEY SAID NEXT STEP WAS A HEADLIGHT ASSEMBLY. HAVE BEEN TRYING TO ORDER ONE AND IT IS NO LONGER AVAILABLE. $1600 FROM DEA…

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DRIVER'S HEADLIGHT QUIT WORKING. TOOK IT TO DEALER, THEY SAID IT WAS THE HEADLIGHT. WASN 'T THE HEADLIGHT. SAID IT WAS THE BALLAST. WORKED FOR 2 MINUTES. THEY SAID THAT TICKET WAS CLOSED AND CHARGED ME $650. THEY SAID NEXT STEP WAS A HEADLIGHT ASSEMBLY. HAVE BEEN TRYING TO ORDER ONE AND IT IS NO LONGER AVAILABLE. $1600 FROM DEALER. LIGHT HAD ACCUMULATED CONSIDERABLE MOISTURE PRIOR TO THE HID ASSEMBLY FAILING. WHEN THE BALLAST WAS REPLACED THE LIGHT FAILED AGAIN BEFORE I ARRIVED HOME 3 MILES AWAY.

NHTSA ODI #11308571

Official recalls

6

26V113000 · Suspension:rear

Feb 26, 2026

General Motors, LLC (GM) is recalling certain 2012–2013 Buick Regal Turbo and GS trim-level vehicles that were sold or ever registered, in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin. The rear suspension toe links may have received improper corrosion protection, which can result in rear toe link fracture.

Consequence & remedy

Consequence: Rear toe link fracture can cause a loss of vehicle control, increasing the risk of a crash.

Remedy: Dealers will replace the rear suspension toe links and adjuster fasteners, free of charge. Owner notification letters were mailed April 3, 2026. Owners may contact Buick customer service at 1-800-521-7300. GM's number for this recall is N252537580. This recall expands previous NHTSA recall numbers 20V764, 21V633, and 21V00F.

21V00F000 · Suspension:rear

Dec 22, 2021

General Motors, LLC (GM) is recalling certain 2010-2013 Buick Lacrosse, 2012-2013 Buick Regal, and 2013 Chevrolet Malibu vehicles sold or ever registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin. These vehicles may have rear toe links that received an improper amount of electrocoating (e-coat) corrosion protection, which could cause the e-coat to become brittle and break away when contacted by road debris. Over time, the e-coat may chip away, exposing the metal toe link and making it more susceptible to corrosion. Corrosion may eventually cause the toe link to thin and ultimately fracture.

Consequence & remedy

Consequence: A rear toe link fracture may reduce the driver's ability to control the vehicle, increasing the risk of a crash.

Remedy: Dealers will replace the rear suspension toe links and adjuster fasteners, free of charge. Owner notification letters were mailed January 27, 2022. Owners may contact Buick customer service at 1-800-521-7300 or Chevrolet customer service at 1-800-222-1020. GM's number for this recall is N212346640. This recall is an expansion of NHTSA recalls 20V-764 and 21V-633.

21V633000 · Suspension:rear

Aug 12, 2021

General Motors, LLC (GM) is recalling certain 2013 Buick Regal, Chevrolet Malibu, and Buick Lacrosse vehicles sold or ever registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin. These vehicles may have rear toe links that received excessive electrocoating (e-coat) corrosion protection, which could cause the e-coat to become brittle and break away when contacted by road debris. Over time, the e-coat may chip away, exposing the metal toe link and making it more susceptible to corrosion. Corrosion may eventually cause the toe link to thin and ultimately fracture.

Consequence & remedy

Consequence: A rear toe link fracture may reduce the driver's ability to control the vehicle, increasing the risk of a crash.

Remedy: Dealers will replace the rear suspension toe links and adjuster fasteners, free of charge. Interim owner notification letters were mailed on September 30, 2021. Owner notification letters were mailed on January 3, 2022. Owners may contact Buick customer service at 1-800-521-7300 or Chevrolet customer service at 1-800-222-1020. GM's number for this recall is N212330130.

20V764000 · Suspension:rear

Dec 21, 2020

General Motors, LLC (GM) is recalling certain 2012-2013 Buick Regal, 2013 Chevrolet Malibu, and 2010-2013 Buick Lacrosse vehicles sold or ever registered in Connecticut, Delaware, the District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, or Wisconsin. These vehicles may have rear toe links that received excessive electrocoating (e-coat) corrosion protection, which could cause the e-coat to become brittle and break away when contacted by road debris. Over time, the e-coat may chip away, exposing the metal toe link and making it more susceptible to corrosion. Corrosion may eventually cause the toe link to thin and ultimately to fracture.

Consequence & remedy

Consequence: A rear toe link fracture may reduce the driver's ability to control the vehicle, increasing the risk of a crash.

Remedy: GM will notify owners, and dealers will replace the rear suspension toe links and adjuster fasteners free of charge. Parts are not currently available. Owners were mailed an interim notification on January 27, 2021, and April 15, 2021. A third notification was mailed on August 19, 201. Owners may contact Buick customer service at 1-800-521-7300 or Chevrolet customer service at 1-800-222-1020. GM's number for this recall is N202308930.

13V173000 · Electrical System

May 6, 2013

General Motors (GM) is recalling certain model year 2012 and 2013 Buick LaCrosse and Regal, and model year 2013 Chevrolet Malibu Eco vehicles equipped with eAssist. These vehicles may have a condition in which the Generator Control Module (GCM) may not function properly. This could cause a gradual loss of battery charge and the illumination of the malfunction indicator light.

Consequence & remedy

Consequence: If the vehicle is continued to be driven, the engine may stall and/or the vehicle may not start. In addition, there may be a burning or melting odor, smoke, and possibly a fire in the trunk.

Remedy: GM will notify owners and dealers will test the GCM and replace it, as necessary, free of charge. The recall began on June 11, 2013. Owners may contact GM at 1-800-521-7300. GM's recall campaign number is 13136.

12V484000 · Exterior Lighting:turn Signal

Oct 4, 2012

General Motors LLC (GM) is recalling certain model year 2011-2013 Buick Regal and model year 2013 Chevrolet Malibu vehicles. These vehicles are equipped with two turn signal bulbs in each front turn signal. If one of the two front turn signal bulbs burn out in either front turn signal lamp, there is no indication to the driver. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard No. 108, "Lamps, Reflective Devices, and Associated Equipment."

Consequence & remedy

Consequence: If the driver is not aware that a turn signal is not functioning properly, the driver may continue to drive the vehicle. If half of a front turn signal is not illuminating, other driver's may not be aware that the affected vehicle is turning, thereby increasing the risk of a crash.

Remedy: GM will notify owners, dealers will update the body control module software, free of charge. The recall began in September 2014. Owners may contact Buick at 1-800-521-7300 or Chevrolet at 1-800-222-1020. GM's number for this recall is 12212.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

AQ14001 · Sands Chevrolet/hybrid System Fire/stall

Opened May 2, 2014 · Closed May 22, 2016

Status: closed (inferred from source dates) · Electrical System

NHTSA opened AQ14-001 to determine whether Sands Chevrolet of Surprise, Arizona complied with the requirements of the National Traffic and Motor Vehicle Safety Act, 49 U.S.C. Chapter 301 (Safety Act) and its implementing regulations. The Safety Act requires, among other things, that a manufacturer notify its dealers of defects related to motor vehicle safety and non-compliances with Federal Motor Vehicle Safety Standards and, in turn, that a dealer not sell and deliver a new vehicle subject to a recall unless the recall remedy has been performed (49 U.S.C. ?? 30112(a), 30120(i)).NHTSA issued an information request (IR) letter to Sands Chevrolet on May 5, 2014.Sands Chevrolet responded to this request on May 22, 2014.To ensure NHTSA?s information request encompassed all possible reference codes for General Motors recall 13V-173, NHTSA issued another IR letter to Sands Chevrolet on June 8, 2015.Again, a response letter was received on June 9, 2015.NHTSA?s investigation indicated that Sands Chevrolet did sell and deliver recalled vehicles that did not have the recall remedy completed at the time the vehicles were delivered to the customers.NHTSA therefore concluded that Sands Chevrolet was liable for civil penalties for violations of the Safety Act, pursuant to 49 U.S.C. ? 30165.Under a Settlement Agreement dated March 24, 2016, Sands Chevrolet represented that it improved its processes to verify that it checks every vehicle for recalls prior to delivery to the purchaser and that it has not sold and delivered any unremedied new motor vehicles since June 9, 2015.Sands Chevrolet also represented that it now also checks for open recalls on every customer vehicle brought in for service, and that it checks for open recalls on every used trade-in vehicle, regardless of make or model, and takes steps to have all used trade-in vehicles repaired prior to retail sale. Sands Chevrolet admitted to violating the law and must pay civil penalties in the amount of $40,000.This Audit Query is closed.

RQ13003 · Generator Control Module Fires

Opened Jul 5, 2013 · Closed Jul 22, 2014

Status: closed (inferred from source dates) · Electrical System:propulsion System:traction Battery

On July 5, 2013 the Office of Defects Investigation (ODI) opened Recall Query RQ13-003 to investigate whether the service procedures utilized in recall bulletins 13136 and 13142 for safety recall 13V-173 were sufficient to identify the safety defect in the subject vehicles.These safety recalls were issue on May 3, 2013 to address the improper function of the Generator Control Module (GCM) in certain model year (MY) 2012-13 Buick LaCrosse and Regal and MY 2013 Chevrolet Malibu Eco equipped with eAssist.This condition may result in a loss of battery charge, engine stall and/or inability for the vehicle to start.In severe cases it may also lead to odor, smoke and possibly a fire in the trunk.During discussions with General Motors (GM), ODI was informed that the subject vehicles could be separated into 4 distinct build populations, or groups. Group A contained vehicles built from the start of production through 3/19/2012.Group B involved vehicles built from 3/20/2012 to 8/20/2012, group C from 8/21/2012 to 12/31/12, and group D from 1/1/2013 onwards.Bulletin 13136 instructed dealers to inspect and, if necessary, replace the GCM for vehicles in groups A or C.Bulletin 13142 instructed dealers to replace the GCM of any vehicle in group B.Group D vehicles were not recalled.All eAssist vehicles have a Powerpack which contains a BAS (belt alternator-starter) Power Inverter Module (BPIM)/Accessory Power Module (APM) and a 115-V Lithium-Ion battery.The Powerpack is known by GM's Part Description System as the GCM and Battery Module. The BPIM/APM contains 3 multi-layered printed circuit boards (PCBs) comprised of conductive layers separated by isolating layers.Vehicles built within the time periods of groups A and B had PCBs using single isolation layers.Vehicles build in group C had dual isolation layers on 1 of the 3 PCBs, and group D had all 3 PCBs built with dual insulation.Adding dual insulation to a PCB makes it more robust to material and manufacturing variations, and ultimately less susceptible to an electrical short circuit and subsequent failure.Through initial analysis of the GCM failures, GM identified that vehicles within group B contained PCBs that were contaminated during production due to increased production volumes that resulted in inadequate quality control.GM also noted that GCM failures occurred early in the life of the vehicle (typically <1000 miles).Therefore a service procedure was developed to replicate early life failures by subjecting the GCM to high current loads which would cause the identified failure mechanism (copper migration) to occur quickly and reveal any underlying PCB defect.Although groups A and C were built with PCBs containing single layer PCBs, they were built using better quality control, and as the data supports, experienced significantly lower failures.GM advised that for these reasons the two different service procedures were used in the Recall 13V-173 population.In response to ODI's Information Request (IR) GM submitted 234 unique reports related to the alleged problem. It was noted that 197 (84%) of the received reports fell into the group B population.The 2 fire incidents noted were events in which flames were evident and/or damage was experienced outside of the GCM. Both of these incidents involved group B vehicles. One hundred four warranty claims were also submitted in response to the IR, with 96 claims (92%) from group B.It was also noted that none of the claims from groups A or C occurred after the service procedure was conducted, and that the majority of the A or C incidents occurred during the service procedure.Given the data, ODI believes the ser