China Tightens EV Safety Rules, Tesla Faces Major Recall

China is intensifying its oversight of electric vehicle safety following years of rapid development in the sector, with Tesla facing the largest impact. The American automaker must recall nearly three million vehicles due to concerns that passengers could have difficulty opening doors after a severe accident and power system failure.

This recall is part of China's largest-ever safety campaign, encompassing about 4.3 million vehicles from nine different manufacturers. Tesla alone is required to address issues with approximately 2.98 million Model 3, Y, S, and X vehicles manufactured or imported into China.

The core of the problem lies with electronic door release systems and mechanical emergency handles. Tesla popularized hidden door handles over a decade ago, a design feature now common in many electric cars. Regulators are now highlighting the safety risks associated with this design, particularly when quick egress is critical.

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The door handle may seem simple, but it becomes a key safety element in the seconds after a crash.

When the power system fails after a severe collision, the electronic door release may not function. In such scenarios, occupants must rely on the mechanical emergency mechanism. Chinese regulators found that these handles on recalled Teslas can be difficult to identify, as they blend in with the interior trim, potentially delaying escape for passengers or hindering access for rescuers.

Concerns have been amplified by accidents where passengers or rescuers reportedly faced difficulties opening doors. In one instance involving a Xiaomi SU7 model in 2025, relatives of the three deceased occupants claimed passengers could not exit the vehicle due to locked doors, though Xiaomi stated the vehicle has mechanical emergency handles that function without electricity. Tesla plans to add clearer markings to the emergency handles on recalled vehicles and will provide a software update that automatically lowers windows after a collision.

Tesla is also facing legal challenges in the United States related to its door design. Following a 2024 Cybertruck crash in California that killed three students, the sole survivor sued Tesla, alleging that the electronic door release failed and the vehicle's design impeded escape from the burning car. Tesla denies these claims.

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Passengers were unable to get out of the car because the doors could not be unlocked.