China has launched the largest automotive recall in the country’s history, with Tesla and eight other automakers recalling approximately 4.3 million vehicles over concerns that emergency door releases could be difficult to locate or operate after a serious crash.
The massive recall comes as Chinese regulators increase scrutiny of vehicle safety, particularly as electric vehicles become increasingly dependent on electronic systems and software. Tesla, Xiaomi, Leapmotor, Xpeng and other major automakers are among the companies affected.
The recalls primarily involve mechanical emergency door-release systems that could be difficult for occupants or rescuers to identify following a collision and electrical system failure.
Tesla Accounts for the Largest Share
Tesla is responsible for the largest portion of the recall, with approximately 2.98 million imported and China-produced vehicles affected.
The recall covers the Model 3, Model Y, Model S and Model X. Tesla is scheduled to begin the recall on September 25.
According to China’s State Administration for Market Regulation (SAMR), the concern is that the mechanical emergency releases may be difficult to identify after a severe collision, potentially delaying occupants trying to escape or rescuers attempting to enter the vehicle.
Tesla’s remedy will include warning labels identifying the emergency release mechanisms. The company will also deploy an over-the-air software update designed to automatically lower the windows after a collision, providing another potential means of access or escape if the electrical system is compromised.
The scale of Tesla’s recall reflects the large number of vehicles equipped with electronically operated or concealed door-opening systems.
Xiaomi, Leapmotor and Xpeng Also Affected
Several Chinese EV manufacturers are facing significant recalls of their own.
Xiaomi will recall approximately 390,435 SU7 sedans from the 2024 model year. The company plans to improve the emergency unlocking logic and power-window operation through software, while also adding warning labels.
Leapmotor is recalling approximately 371,200 C11 and C01 vehicles. The remedy includes warning labels and an upgrade to the power-window control software.
Xpeng will recall approximately 264,842 vehicles, covering the G6, P7+ and X9 model ranges.
Zeekr is also affected, with approximately 92,658 units of the 007 and X models subject to corrective measures.
Additional recalls involving Chery, Dongfeng, Arcfox and FAW include measures such as improved markings, warning labels and replacement of covers around mechanical emergency releases.
Most of the remedies are relatively straightforward compared with traditional mechanical recalls. Automakers can use OTA software updates for some fixes, while physical work is largely limited to labels, markings or replacement components.
Why China’s EV Door Handle Rules Are Changing
The recall comes as China prepares to introduce tougher requirements for vehicle door systems.
Starting in 2027, China is set to become the first country to broadly restrict the use of concealed or retractable door handles in their current form on new vehicles.
These designs have become increasingly common on modern EVs, with Tesla helping popularize flush and electronically operated door handles. Many Chinese electric cars have subsequently adopted similar designs.
The safety concern is straightforward: if a vehicle loses electrical power following a major crash, an electronic door handle may no longer function normally.
Mechanical emergency releases are intended to provide an alternative, but they can be difficult for occupants unfamiliar with the vehicle to find, particularly in darkness, smoke or the confusion immediately following an accident.
That has also raised concerns about whether rescuers outside a damaged vehicle can quickly determine how to open its doors.
Safety Concerns Extend Beyond China
The issue is not limited to China’s automotive market.
U.S. regulators have also been examining the potential safety risks associated with electronically operated door handles. The National Highway Traffic Safety Administration has said it is considering new safety requirements addressing the risk of occupants becoming trapped when a vehicle loses electrical power.
NHTSA said Friday that automakers had not notified the agency of plans to file a similar recall in the United States related to the Chinese action.
The issue has received additional attention following crashes involving EVs in which emergency responders or bystanders have encountered difficulties opening the doors.
The growing use of software-controlled vehicle functions means automakers increasingly have to consider what happens when power, communication systems or electronic controls are unavailable after a crash.
China’s EV Market Makes the Recall Significant
The timing of the recalls is particularly important because China’s EV market has become the largest and most influential in the world.
New Energy Vehicles (NEVs) accounted for 60.4% of China’s new-car sales in July, with approximately 1.56 million units sold.
China is also becoming a major export hub for electric vehicles. Around 553,000 NEVs were exported in July, representing a 145.5% increase from the same month a year earlier. NEVs accounted for more than half of China’s vehicle exports for the second consecutive month.
As Chinese EV manufacturers expand into Europe, Southeast Asia, Australia and other markets, safety standards developed in China could increasingly influence vehicle designs sold internationally.
The shift away from concealed door handles could therefore become a broader industry trend rather than a regulation affecting only Chinese-market vehicles.
Tesla Faces Another Major China Recall
The emergency door-release recall is not Tesla’s only major recall announced in China.
Separately, approximately 2.74 million Tesla Model 3 and Model Y vehicles are being recalled over concerns about the vehicle’s driver-monitoring system.
China’s regulators determined that Tesla’s existing system, which relies partly on steering-wheel torque to monitor driver attention, does not meet local requirements.
Tesla plans to address the issue through an OTA software update that will incorporate the vehicle’s interior camera into the monitoring system.
Combined with the emergency door-release recall and other actions announced by Chinese regulators, the number of vehicles affected by recalls involving Tesla and other automakers exceeds seven million.
