The carmaker said the battery defects were caused by a screening process added to the production line in December 2012, in which the units had been exposed to an excessive force, generating debris which had led to a short circuit.

A recall for 3,839 Outlander PHEVs and 68 Minicab-MiEVs, all of which are located in Japan, was issued this week, and the screening process responsible has now been removed from the production line. Mitsubishi has advised Outlander customers not to use external charging until their vehicle has been recalled.

Versions of the i-MiEV sold outside Japan are understood not to be affected by the defect, which will also be rectified before the Outlander PHEV goes on sale globally later this year.