Geely Auto Recalls Polestar 4 EVs Over Battery Thermal Runaway Risk

Geely Auto has initiated a recall of 1,473 units of the Polestar 4 electric vehicle due to identified risks associated with battery thermal runaway. The affected vehicles are equipped with 86 kWh battery packs and were produced within a defined manufacturing window. The recall highlights ongoing challenges in ensuring battery safety as electric vehicle adoption accelerates globally, particularly in high-voltage systems where even minor inconsistencies can escalate into critical safety concerns.

Manufacturing Defect and Battery Risk Explanation

The recall impacts vehicles manufactured between November 16, 2023, and May 24, 2024. According to the China State Administration for Market Regulation, inconsistencies in high-voltage battery component manufacturing may cause abnormal increases in internal resistance over prolonged usage. This deviation can reduce battery efficiency and performance. In severe scenarios, the condition could trigger thermal runaway, a hazardous chain reaction that can lead to overheating and potential fire risks in electric vehicles.

Customer Advisory and Recall Execution Plan

To mitigate immediate risks, customers are advised to restrict battery charging to no more than 70% during daily use until corrective actions are completed. Geely Auto has authorized Polestar's sales network to manage the recall process. The company will replace the affected battery modules at no cost to vehicle owners. This proactive measure aims to ensure safety while maintaining customer trust and minimizing operational disruptions for users.

Comparison with Previous Recall Events

This recall follows a similar action earlier in the year involving Zeekr, another brand under the Geely Auto umbrella. In that instance, 38,277 Zeekr 001 WE edition vehicles were recalled due to comparable thermal runaway risks linked to battery systems. The recurrence of such issues indicates systemic challenges in battery manufacturing consistency across multiple platforms within the group’s electric vehicle portfolio.

Battery Supplier Dispute and Financial Implications

The earlier Zeekr recall was tied to a dispute between a Geely Auto subsidiary and battery supplier Sunwoda. The disagreement escalated into legal action, with compensation claims reaching up to 2.31 billion yuan. Eventually, both parties reached an agreement to share repair costs proportionally based on actual expenses incurred. This resolution underscores the financial and operational risks associated with battery supply chain dependencies.

Uncertainty Around Supplier Linkage

At present, it remains unclear whether the Polestar 4 recall is directly connected to the same supplier-related issues involving Sunwoda. However, the similarity in defect characteristics suggests potential overlaps in component sourcing or manufacturing processes. Further clarity may emerge as investigations continue and additional technical assessments are conducted by regulatory authorities and manufacturers.

Polestar 4 Recall Details Overview

The following table summarizes the key details of the recall event for quick reference.

Frequently Asked Questions

Why is the Polestar 4 EV recall happening?
The recall is due to manufacturing inconsistencies in high-voltage battery components that may increase internal resistance over time, potentially causing performance degradation and, in extreme cases, thermal runaway risks. This safety concern prompted regulatory action and a preventive recall. Affected vehicles are being repaired through battery module replacement, ensuring long-term safety and compliance. Customers are advised to follow interim charging guidelines until corrective measures are completed to reduce potential risks.