China has launched its largest-ever vehicle recall, affecting more than four million electric vehicles over concerns that their sleek, concealed door handles could make it difficult for occupants to escape during emergencies.
The recall affects about 4.1 million vehicles, including 2.98 million Tesla cars manufactured in China. Other manufacturers involved include Chinese electric vehicle makers XPeng, Xiaomi and Geely.
The safety concerns centre on electronic and flush-mounted door handles used in many modern EVs. Authorities are concerned that the handles could become difficult to find or operate following a crash, particularly if the vehicle loses electrical power.
Under the recall measures, affected vehicles will receive warning labels showing how to operate the doors. Manufacturers will also introduce software updates designed to automatically lower the windows following a collision, potentially making it easier for occupants and rescuers to gain access.
Tesla confirmed on Friday that some Model 3, Model Y, Model S and Model X vehicles were being recalled because their door handles can be “difficult to identify and operate because their colour is similar to the interior trim”.
The company explained that the problem could become particularly dangerous when a serious collision causes the vehicle’s low-voltage electrical system to fail.
“In extreme situations such as a severe collision causing the vehicle’s low-voltage system to fail, this could hinder occupants from quickly opening the doors to escape and impede rescue efforts by those outside the vehicle, posing a safety hazard,” Tesla said.
The recall comes amid increased scrutiny of concealed door-handle designs following two fatal crashes in China involving Xiaomi electric vehicles. Power failures were reportedly suspected of preventing the doors from being opened.
The minimalist handles became increasingly popular among Chinese EV manufacturers after Tesla introduced similar styling on its Model S in 2014.
Tu Le, founder of consultancy Sino Auto Insights, said the design had “snowballed” as Chinese manufacturers adopted the sleek appearance.
However, he described the warning labels and software changes being introduced as more of a “band-aid” than a permanent solution.
China is moving towards stricter requirements for vehicle door safety. From January 1, 2027, new rules will require vehicles sold in the country to have a mechanical door release on both the inside and outside.
It remains unclear whether the affected manufacturers will introduce similar recalls or modifications for vehicles sold outside China.
The issue is also attracting attention in the United States, where the National Highway Traffic Safety Administration proposed in July that a new formal safety standard should be developed for vehicle door-release systems across the industry.
