Tesla and eight other automakers are set to recall about 4.3 million vehicles in China over concerns that occupants could struggle to open the doors during emergencies, making the action the largest automotive recall recorded in the country.
The recall affects vehicles fitted with emergency mechanical door-release systems that regulators say may be difficult to locate or operate following a serious crash, particularly when the vehicle's electrical system has failed.
The remedies vary among manufacturers, ranging from software updates and warning labels to improved markings designed to make emergency door handles easier to identify.
The large-scale recall comes as Chinese authorities intensify scrutiny of the country's rapidly expanding electric vehicle industry. Automakers are competing aggressively on price while simultaneously introducing increasingly sophisticated software, electronic controls and new vehicle designs in the world's largest automotive market.
China has also announced plans to prohibit concealed door handles from 2027, making it the first country to phase out a design popularised by Tesla and subsequently adopted by numerous Chinese electric vehicle manufacturers.
Tesla Accounts for Largest Share
Tesla's action represents the biggest portion of the recall, involving approximately 2.98 million imported and China-made Model 3, Model Y, Model S and Model X vehicles.
According to a statement from China's State Administration for Market Regulation (SAMR), the Tesla recall will begin on September 25.
The regulator said Tesla vehicles could present difficulties for occupants or rescuers in certain severe collisions because the mechanical emergency door-release handles may be difficult to identify after an impact and electrical power failure.
Tesla's remedy includes placing warning labels inside the vehicles to identify the emergency releases and deploying an over-the-air software update.
The software modification will automatically lower the vehicle windows after a collision under specified circumstances, potentially making it easier for occupants to escape or rescuers to gain access.
Tesla did not immediately respond to a request for comment.
Xiaomi, Leapmotor and Xpeng Also Affected
Several Chinese electric vehicle manufacturers are also undertaking substantial recalls.
Xiaomi will recall about 390,000 vehicles, while Leapmotor will recall approximately 371,000 and Xpeng about 264,000, according to filings with the Chinese regulator.
For Leapmotor, the corrective measures involve installing a warning label and upgrading power-window control software.
The company said it remained committed to vehicle safety and described its decision to carry out the action as part of its responsibility to customers.
“Managing and filing it in accordance with the recall process out of a sense of responsibility to our users,” Leapmotor said.
Geely Holding and several other manufacturers have also filed recall notices, although their campaigns are considerably smaller.
Geely and Xpeng declined to comment, while Xiaomi said it had no additional information beyond the regulatory notice.
Concerns Over Trapped Occupants
The recall centres on emergency mechanical door releases, which are intended to provide a way out when conventional electronic door-opening systems are unavailable.
Regulators' concerns have been heightened by incidents in which occupants were reportedly unable to escape damaged or burning vehicles.
Chinese state media reported in October that the driver of a Xiaomi SU7 sedan died after a crash and subsequent fire, with reports indicating that bystanders were unable to open the vehicle doors to rescue him.
The incident has added to concerns over concealed or electronically operated door handles, particularly in vehicles where an electrical failure can complicate access.
Software Offers Cheaper Fix
The scale of the recall reflects the enormous size of China's vehicle market but also highlights the increasing role of software in modern automobiles.
Most of the affected manufacturers will use over-the-air updates to modify vehicle systems without requiring owners to take their cars to dealerships.
Warning labels identifying emergency door handles will also be installed free of charge.
Sam Fiorani, vice-president of research at AutoForecast Solutions, said the financial impact on manufacturers could be relatively limited because many of the corrective measures can be carried out digitally.
“Modern over-the-air updates reduce the costs and downtime associated with major recalls and even the physical work needed to be done will not be very costly compared to significant recalls of the past,” Fiorani said.
The development illustrates how software-based vehicle architecture is changing the economics of recalls, allowing manufacturers to address certain safety concerns remotely rather than undertaking extensive physical repairs.
China Tightens Automotive Rules
The recall comes against the backdrop of growing regulatory scrutiny of China's automotive sector.
Beijing has introduced tougher safety requirements as manufacturers compete in an increasingly crowded electric vehicle market and race to offer new technologies at lower prices.
Concealed door handles have emerged as one area of particular concern.
The design, which can improve aerodynamics and contribute to a sleek exterior appearance, has become increasingly common in electric vehicles. However, critics argue that occupants and rescuers may struggle to locate and operate the mechanisms during an emergency, especially after a collision or power failure.
China's decision to ban concealed door handles from 2027 is expected to have significant implications for vehicle design and could influence manufacturers well beyond the Chinese market.
U.S. Regulators Also Watching
The issue has attracted attention in the United States as well.
The National Highway Traffic Safety Administration (NHTSA) said last month that it would consider new safety standards aimed at addressing the risk of occupants becoming trapped inside vehicles during electrical power failures.
NHTSA said late Friday, however, that automakers had not notified the agency of plans to file a similar recall for vehicles sold in the United States.
The developments in China could nevertheless intensify international scrutiny of electronically operated and concealed vehicle door systems as automakers increasingly rely on digital controls.
With approximately 4.3 million vehicles affected, the Chinese recall represents a significant test of how regulators and manufacturers respond to safety risks created by the rapid evolution of vehicle technology.
It also underscores a growing challenge for the global automotive industry: ensuring that design innovations intended to improve convenience, efficiency and aesthetics do not compromise the basic ability of occupants and rescuers to open a vehicle's doors when lives depend on it.