BYD initiates recall of almost 90,000 vehicles in China after identifying critical failure in battery modules

The world’s largest manufacturer of new energy vehicles has officially issued a large-scale recall procedure in the Chinese market, affecting a significant portion of its circulating fleet. The measure, filed with Administração Estatal of Regulação of Mercado (SAMR), aims to correct a manufacturing defect identified in units of the Qin Plus DM-i plug-in hybrid sedan. The problem is located in the battery pack production process, which could compromise the operational safety of the cars involved.

The safety recall covers a total of 88,981 vehicles produced during a specific two-and-a-half-year period. The affected units left the assembly line between January 2021 and September 2023. Segundo the technical report presented to regulatory authorities, the failure could lead to a sudden loss of power while the vehicle is in motion, creating a risk of accidents and collisions on public roads.

Internal investigations revealed that inconsistency in battery pack tray manufacturing may cause insufficient voltage on certain components. In extreme situations or continuous use, this structural fragility has the potential to result in overheating or serious electrical failures, forcing the manufacturer to intervene preventively to guarantee the physical integrity of occupants and third parties.

This move comes at a time of heightened vigilance by Chinese regulators over the quality of electric and hybrid vehicles. The company’s proactive action seeks to mitigate damage to the brand’s image, which leads global sales in the sector, and ensure that the safety standards required by local legislation are strictly complied with through the necessary technical corrections.

Repair strategy via remote update

To resolve the technical issue without causing excessive inconvenience to owners, the automaker developed a hybrid repair approach. The first step is to make an over-the-air (OTA) software update available, which will be sent remotely to connected vehicles. Este new software has the ability to monitor battery cell behavior with greater accuracy and identify voltage anomalies in real time.

If the updated diagnostic system detects any physical irregularity or imminent risk in the battery module, a notification will immediately be displayed on the vehicle’s instrument panel. The alert will instruct the driver to contact an authorized dealer for a detailed physical inspection. Nessas confirmed situations, the company will completely replace the defective battery pack, at no cost to the consumer, guaranteeing the definitive resolution of the problem.

Sales context and market performance

The recall announcement coincides with the release of the company’s commercial results for the month of October, which show a mixed scenario of growth and adjustments. The automaker recorded the sale of more than 44 thousand units in the period, which represents a significant increase compared to the same month of the previous year. However, there was a slight decline in the plug-in hybrid segment, the category to which the model affected by the recall belongs.

While pure electric vehicles (BEV) continue to show robust growth rates, with a double-digit increase in monthly sales, hybrid models face stiffer competition in the Chinese domestic market. The recall of the Qin Plus DM-i units is seen by analysts as a test of the company’s logistical ability to manage its huge customer base while maintaining the rapid pace of international expansion and new product launches.

Transparency in the recall process is essential to maintain consumer confidence in a highly competitive market. The company reiterated its commitment to quality and stated that all owners of affected units will be notified through official channels, including brand apps and registered mail, to schedule the necessary checks as soon as possible.

Recent history of security actions

This is not the first time this year that the manufacturer has needed to make adjustments to its product line to comply with safety standards. Meses previously, the company had already summoned owners of the Dolphin and Yuan Plus models for corrections to components of the electric steering system, demonstrating that the exponential increase in production brings with it complex quality control challenges on an industrial scale.

The recurrence of corrective actions is a phenomenon observed in several automakers that operate with mass electrification technologies. As vehicles become more dependent on complex software and high-voltage battery systems, the need for constant monitoring and after-sales updates becomes an integral part of the modern automotive product lifecycle.