Tesla, Xiaomi, Xpeng, Leapmotor recall 4.3 million EVs in China over door safety

BEIJING: When a door becomes a sticking point, it is usually a minor nuisance. For China’s electric vehicle industry, it has become a record-breaking recall.

Tesla and eight other automakers are recalling about 4.3 million vehicles in China over concerns that their doors could be difficult to open during an emergency, marking the country’s largest automotive recall, according to Reuters.

The recall centres on electronic or concealed door handles, a design popularised by Tesla and now widely used by electric vehicle makers. Regulators are concerned that emergency mechanical door releases may be difficult to find or operate after a serious crash, particularly if the vehicle loses electrical power.

Tesla accounts for the biggest share of the recall. The company will recall about 2.98 million imported and China-made Model 3, Model Y, Model S and Model X vehicles from September 25, according to a filing with China’s State Administration for Market Regulation.

Tesla’s fix will include warning labels and a remote software update designed to automatically lower vehicle windows after a collision, helping occupants and rescuers gain access when the electrical system fails.

The scale of the action reflects the rapid spread of flush-fitting electronic door handles across China’s booming EV market. The handles are designed to sit almost level with the bodywork, giving cars a cleaner appearance and potentially improving aerodynamics. But that sleek design can become less intuitive when a vehicle is damaged or loses power.

Xiaomi will recall about 390,000 vehicles, while Leapmotor is recalling roughly 371,000 and Xpeng about 264,000.

Leapmotor said its action involves adding a warning label and upgrading power-window control software, describing the move as part of its responsibility towards users. Xiaomi said it had no additional information beyond the regulatory notice, while Xpeng and Geely declined to comment to Reuters.

Several of the manufacturers involved are undertaking their largest recalls on record. Most will use over-the-air software updates, warning labels or clearer markings around emergency door handles rather than extensive physical repairs.

That could keep the cost and disruption relatively low. Sam Fiorani, vice president of research at AutoForecast Solutions, said modern over-the-air updates can reduce both the expense and downtime associated with large recalls.

The recall comes as Beijing steps up scrutiny of the country’s fiercely competitive EV industry. Automakers have been rapidly adding new technologies while cutting prices in an increasingly intense market, putting greater pressure on regulators to address safety concerns.

China has already announced plans to ban concealed door handles from 2027, making it the first country to phase out the design. The move could force automakers to rethink a feature that has become closely associated with modern electric vehicles.

The issue has also attracted attention outside China. US regulators are considering new safety standards addressing the risk of occupants becoming trapped when electronic door systems lose power. European regulators have likewise flagged door-handle safety, while international authorities are working on standards for emergency access when a vehicle’s electrical system is disabled.

The safety concerns are not purely theoretical. Chinese state media previously reported that the driver of a Xiaomi SU7 died after a crash and fire in which people attempting to help were unable to open the vehicle’s doors.

For Tesla and its Chinese rivals, the message from regulators is increasingly clear: a futuristic door handle is only as useful as the emergency exit behind it. With 4.3 million vehicles now subject to recall, the industry’s race for sleek design is facing a very practical safety check.