4.3m vehicles recalled in China over safety risks; Tesla accounts for 2.98m

Over 4.3 million vehicles in China have been recalled due to safety concerns related to emergency door-opening systems, marking the nation’s largest automotive recall. The initiative includes 2.98 million Tesla vehicles, alongside hundreds of thousands from Xiaomi, Leapmotor, Xpeng, Geely and other manufacturers. The recall follows regulatory warnings that occupants might struggle to open doors during emergencies, especially if a crash disables the vehicle’s electrical system. The affected models include Tesla’s Model 3, Model Y, Model S and Model X, both imported and produced within China. The recall process begins on September 25, with remedies involving software modifications and warning labels designed to improve identification of emergency release mechanisms. The recall comes amid intensified scrutiny of China’s new-energy vehicle (NEV) sector, as regulators tighten safety oversight. The issue stems from the widespread adoption of electronically controlled and concealed door systems, a feature closely linked to Tesla’s designs. These systems, while enhancing aerodynamics and aesthetics, pose challenges in emergency situations. China announced in February that it would ban concealed door handles on vehicles starting in 2027, prompting automakers to adjust their strategies. The current recalls represent a proactive step toward aligning with these future regulations. Xiaomi, Leapmotor, Xpeng and Geely have all issued recalls, with Xiaomi recalling over 390,000 vehicles and Leapmotor recalling approximately 371,000. Xpeng is recalling around 264,000 units, while Geely and other manufacturers are addressing smaller numbers. Corrective actions vary among companies. Some are adding visible labels to indicate emergency release points, while others are implementing over-the-air software updates to modify post-collision behavior. Leapmotor, for instance, is incorporating a warning label and upgrading its power-window control software as part of its solution. The safety concerns have been exacerbated by real-world incidents. In October, Chinese state media reported that a Xiaomi SU7 driver died after a crash and subsequent fire, with witnesses unable to open the vehicle’s doors. This incident highlights the potential dangers of electronically operated doors. Cui Dongshu, head of the China Passenger Car Association, noted that the recalls reflect the industry’s transition toward higher safety standards. He emphasized that while the recalls signal growth pains, they also underscore a policy-driven push for improved safety protocols. The People's Daily described the recalls as a “unified safety upgrade” ahead of the 2027 ban on concealed door handles, stressing that safety must be a key benchmark for the fast-evolving NEV industry. Beyond China, the issue is gaining attention in the United States. Regulators there are evaluating whether electronically operated and concealed door systems could trap occupants during power loss. The National Highway Traffic Safety Administration (NHTSA) has reportedly considered new safety standards to mitigate such risks. However, as of late Friday, NHTSA stated that automakers had not yet notified it of planned recalls in the U.S. While the potential scope of affected vehicles is vast, the financial impact on manufacturers may remain limited. Many of the necessary fixes can be implemented remotely through over-the-air updates, reducing costs and minimizing disruption. Sam Fiorani, vice president of research at AutoForecast Solutions, highlighted that these remote solutions significantly cut down on traditional expenses and operational delays typically associated with large-scale recalls.