Nissan Launches Urgent Global Recall of Leaf Electric Vehicles Amid Systemic Safety Concerns

In a striking development underscoring the critical importance of safety in the rapidly expanding electric vehicle (EV) market, Nissan has announced a sweeping, worldwide recall affecting multiple generations of its flagship Nissan Leaf. This action follows the detection of systemic faults in the Battery Management System (BMS)—the vital component responsible for monitoring and controlling lithium-ion battery health. The move not only demonstrates Nissan’s commitment to consumer safety but also highlights broader industry challenges in ensuring the reliability of EV battery systems as global adoption accelerates.

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Widening Scope of the Recall: From Isolated Incidents to Systemic Faults

Initially, Nissan's recall initiatives targeted specific model years following isolated reports of vehicle fires and battery malfunctions. However, recent investigations—supported by field data, regulatory insights, and consumer reports—reveal that faulty BMS algorithms are impacting newer Leaf models and multiple production batches. This indicates a systemic issue rather than isolated defects, emphasizing an urgent need for comprehensive intervention.

Key Issues Identified:

• Defective Battery Management Software: The BMS software, engineered to oversee battery parameters, has been found to trigger temperature irregularities and overvoltage conditions.
• Thermal Runaway Risks: Malfunctions can lead to thermal runaway, a dangerous chain reaction within lithium-ion batteries that can cause fires, explosions, or unexpected power shutdowns.
• Confirmed Incidents: Numerous cases of battery fires and sudden power failures have been directly linked to software faults in the BMS, prompting regulatory warnings across several countries.

Recent Developments:

• Field data shows that both older and newer Leaf models, including the latest B7 series and upcoming models, are affected.
• Regulatory agencies in multiple regions have issued advisories urging affected owners to heed safety notices and schedule inspections promptly.
• Customer reports of fire incidents and abrupt power losses have increased, raising serious safety concerns.

In response, Nissan has initiated an extensive global recall campaign, offering free diagnostics, inspections, and repairs at authorized service centers worldwide. The automaker emphasizes transparent communication and swift action to mitigate safety risks and maintain consumer trust amid the EV boom.

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Important Owner Actions and Support Measures

Nissan strongly advises affected owners to:

• Verify their Vehicle Identification Number (VIN) via Nissan’s official website or through direct notifications.
• Schedule inspections without delay at authorized Nissan service centers.
• Cease driving immediately if instructed, until repairs are completed, to reduce fire risk.
• Stay informed through official Nissan advisories for further instructions.

Support programs include:

• Free diagnostics and battery inspections worldwide.
• Depending on the fault severity, repairs may involve:
  • Battery module replacements
  • Full pack reconditioning
  • Complete pack replacements

While battery replacements outside of warranty may cost between $5,000 and $15,000, Nissan has announced financial assistance programs to support affected customers, demonstrating its commitment to customer safety and transparency.

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Industry Response: Technical and Regulatory Reforms

This widespread issue with BMS software underscores broader industry challenges:

• The critical need for stringent quality control in battery manufacturing.
• The importance of advanced thermal management systems to prevent overheating and thermal runaway.
• The fragility of global supply chains, especially for raw materials like lithium and cobalt.

Experts emphasize that rigorous safety testing, standardized protocols, and innovative battery chemistries—such as solid-state batteries—are essential to prevent similar faults in future models. The incident acts as a catalyst for industry-wide reforms, compelling automakers to prioritize safety, transparency, and long-term quality assurance.

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Future Model Developments and Nissan’s Strategic Response

Testing of Nissan Leaf B7 and Upcoming ZE2

To restore consumer confidence, Nissan is actively testing the third-generation Nissan Leaf B7, which is currently undergoing refinement and validation. Industry sources, including GQ JAPAN, report that the B7 series features refined exterior design, improved driving dynamics, and increased range—all aimed at rebuilding trust.

Looking ahead, Nissan plans to launch the Leaf ZE2 in January 2026, which will feature:

• 55 kWh batteries for extended range
• Enhanced BMS with more sophisticated algorithms to prevent thermal issues
• State-of-the-art thermal management systems designed to reduce overheating risks
• Stringent manufacturing standards to prevent systemic faults

The ZE2 is positioned to set new benchmarks in safety, durability, and cost efficiency, reaffirming Nissan’s ambition to lead in next-generation EV technology.

Industry Movements:

• Automakers are emphasizing battery durability and thermal management in upcoming models.
• Local manufacturing expansions, such as Nissan’s scaled-up production at the Guangzhou plant, aim to improve quality control.
• Significant investments in next-generation batteries—including solid-state chemistries—are ongoing to enhance safety and performance.

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Supporting Infrastructure and Market Dynamics

Efforts to bolster EV adoption include accelerated deployment of high-capacity charging networks:

• Terra Charge, in collaboration with Komeri, is deploying 120 kW fast chargers at 27 retail stores across Japan starting February 16. These chargers can recharge EVs to 80% capacity in approximately 15–20 minutes, alleviating range anxiety.
• Lawson is installing ultra-fast chargers at urban locations.
• E-Mobility Power has upgraded East and West Ebina Service Areas with high-power rapid chargers suitable for long-distance travel.
• Keysight Technologies has introduced megawatt-level EV charging test solutions to facilitate robust safety testing of high-power chargers, promoting industry safety standards.

Market Trends in Japan

• EV sales surged by 43% in January 2026, with market share surpassing 2% of new vehicle registrations.
• The Toyota bZ4X experienced an astonishing 66-fold increase in sales, reflecting growing consumer confidence.
• Imported EVs now account for approximately 12.6% of new registrations, indicating a more diversified market landscape.

The expansion of fast-charging infrastructure and technological innovation are expected to accelerate EV adoption and improve user experience.

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Industry Collaborations and Next-Generation Technologies

Urban EV Initiatives and Component Innovations

Japanese startups like KG Motors, supported by Toyota Gosei, are collaborating with Cosmo Oil to develop affordable, compact city EVs such as the MiBot. Designed for short urban trips, the MiBot aims to integrate existing fueling infrastructure with EV charging, enhancing urban mobility accessibility.

This partnership exemplifies the hybrid ecosystem—combining traditional fueling stations with EV charging—which is vital for wider acceptance in densely populated areas where charging infrastructure expansion faces challenges.

Industry Trends

• Focus on local manufacturing and supply chain resilience to ensure quality assurance.
• Development of next-generation batteries, including solid-state chemistries, offering higher safety margins and longer lifespan.
• Integration of renewable energy sources into charging networks to reduce carbon footprints.

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Current Status and Industry Outlook

The recall campaign continues globally, with affected owners being notified directly and urged to schedule repairs promptly. Nissan remains committed to transparent communication and customer safety.

While this incident presents a significant safety challenge, it is also catalyzing industry-wide improvements:

• Enhanced manufacturing quality controls
• More resilient thermal management systems
• The development of safer, more reliable batteries, including solid-state options

This event underscores that safety and transparency are fundamental for the long-term growth of EVs. Automakers are investing heavily in next-generation batteries, recycling initiatives, and charging infrastructure to restore consumer confidence and accelerate adoption.

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Final Thoughts and Industry Implications

The Nissan Leaf recall exemplifies the critical importance of safety standards in the EV sector. Addressing systemic faults is essential to build consumer trust and ensure sustainable growth. As Nissan works to resolve current issues with models like the Leaf B7 and the ZE2, the broader industry is learning and evolving.

Key takeaways include:

• The necessity for stringent quality control and advanced thermal management
• The push toward next-generation, safer battery chemistries
• The importance of robust charging infrastructure and urban mobility solutions

Ultimately, safety and transparency will determine the future trajectory of EV adoption. Nissan’s proactive measures and model innovations are steps toward restoring confidence and paving the way for a more reliable, sustainable electric mobility ecosystem that meets the demands of a cleaner, greener future.

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Additional Industry Insight: The Role of SiC Power Semiconductors

In a related development highlighting component safety and performance, Japanese semiconductor manufacturer ROHM has garnered attention. Despite over 50 Chinese EV companies sourcing SiC (Silicon Carbide) power semiconductors from various suppliers, Japanese-made SiC components continue to lead the industry in quality, reliability, and safety.

A recent YouTube video, titled 【ローム衝撃】中国EV50社が束になっても越えられない...日本製SiCの壁とは (ROHM Shock: Even 50 Chinese EV Companies Can't Surpass... The Wall of Japanese SiC), emphasizes that Japanese SiC semiconductors remain the gold standard for power conversion efficiency, thermal stability, and long-term durability. This technological advantage is crucial as EV manufacturers rely increasingly on SiC devices to improve performance and safety.

Implication: The dominance of Japanese SiC technology underlines the importance of rigorous component quality assurance, particularly in critical systems like power inverters and battery management. Ensuring component reliability is vital to prevent failures and uphold vehicle safety standards.

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Conclusion

The Nissan Leaf recall marks a pivotal moment in the EV industry, illuminating systemic challenges in battery safety and management. Through comprehensive recalls, technological upgrades, and industry collaborations, Nissan and other automakers are working to restore consumer confidence and raise safety standards. Simultaneously, advancements in component technology, such as Japanese SiC semiconductors, reinforce the foundation for safer, more reliable EVs.

As the industry continues to evolve, safety, transparency, and innovation will be the guiding principles shaping the future of electric mobility—ensuring EVs are not only environmentally friendly but also trustworthy and safe for consumers worldwide. The ongoing efforts demonstrate that addressing systemic issues head-on is key to building a sustainable, resilient EV ecosystem capable of meeting the demands of a greener future.