1995-1999 Mitsubushi CARISMA Service Manual Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Carisma Model Generation: First Generation Model Years Covered: 1995, 1996, 1997, 1998, 1999 Codes Platform Code: DA1A (sedan), DA2A (hatchback) 👋 Introduction Market Position Segment: Compact Family Car / Small Family Car Market Role: Offered a practical, well-equipped alternative in a competitive segment Competitive Analysis Key Competitors: Ford Focus, Volkswagen Golf, Opel Astra, Toyota Corolla, Honda Civic, Renault Mégane Key Features Design Philosophy: European styling cues, emphasis on practicality and value Body Styles: Offered in both 4-door Sedan and 5-door Hatchback variants Interior Layout: Ergonomic dashboard, good passenger space for its class 📋 Manual Details Coverage Areas Primary Regions: Europe, Asia, Australia Regions Not Typically Covered: North America (due to different model lineups) Page Count Estimated Page Count: 1500+ Manual Type Type: Comprehensive Service and Repair Manual Language Language: English Format Format: Digital (PDF), Printable 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, and reassembly of all engine components Engine Electrical: Ignition system, fuel injection system (ECI), starting system, charging system, sensors, actuators, ECU diagnostics Transmission Manual: Clutch system, gearbox overhaul, gear selection mechanisms, shift linkage Transmission Automatic: ATF diagnosis, torque converter, valve body, planetary gear sets, hydraulic control systems Chassis Suspension: Front MacPherson struts, rear multi-link suspension, bushings, shock absorbers, springs, anti-roll bars Chassis Steering: Power steering system (pump, rack, hoses), steering column, universal joints Chassis Brakes: Front ventilated discs, rear discs/drums, hydraulic system, ABS (if equipped), brake pads, calipers, master cylinder Electrical Body: Lighting systems (headlights, taillights, interior), power windows, central locking, mirrors, wipers, horn HVAC: Air conditioning system (refrigerant, compressor, evaporator, condenser), heating system, climate control Body And Trim: Body panel removal and installation, interior trim components, glass replacement, weatherstripping Procedures Included Scheduled Maintenance: Detailed maintenance schedules and procedures for all intervals Diagnostic Procedures: Step-by-step troubleshooting guides for common and complex faults, DTC interpretation Repair Procedures: Detailed instructions for component removal, repair, and reinstallation Component Rebuilds: Instructions for overhauling engines, transmissions, and other major components Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Specification Charts: Torque specifications, clearance measurements, electrical values Technical Depth Depth: Extremely high; covers everything from basic fluid changes to full engine and transmission rebuilds and advanced electrical diagnostics 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text for quick information retrieval Print Quality Printability: High-resolution, printable pages Binding Type Binding Style: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Petrol 1.3L: 4G13 (SOHC) Engine Code Petrol 1.6L: 4G92 (DOHC MPI) Engine Code Petrol 1.8L: 4G93 (DOHC MPI) Engine Code Diesel 1.9L: 4D68 (Naturally Aspirated Diesel), 4D68T (Turbocharged Diesel) Performance 1.6L Horsepower: 103 PS (76 kW; 102 hp) at 6000 rpm Torque: 137 Nm (101 lb-ft) at 4300 rpm Performance 1.8L Horsepower: 116 PS (85 kW; 114 hp) at 6000 rpm Torque: 161 Nm (119 lb-ft) at 4500 rpm Fuel System Injection Type Petrol: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (RON 91-95), Diesel Engine Construction Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy 🔧 Transmission Standard Transmission Type Petrol: 5-speed Manual Optional Transmission Type Petrol: 4-speed Automatic (INVECS-II with adaptive shift logic) Transmission Type Diesel: 5-speed Manual Features Clutch Type: Hydraulically actuated dry single plate clutch Fluid Specs Manual Transmission Fluid Type: API GL-4 SAE 75W-90 or SAE 75W-85 Automatic Transmission Fluid Type: Diamond ATF SP-II M or equivalent 📐 Dimensions Exterior Sedan Length: Approx. 4435 mm (174.6 in) Width: Approx. 1745 mm (68.7 in) Height: Approx. 1415 mm (55.7 in) Exterior Hatchback Length: Approx. 4315 mm (169.9 in) Width: Approx. 1745 mm (68.7 in) Height: Approx. 1425 mm (56.1 in) Wheelbase Wheelbase: Approx. 2600 mm (102.4 in) Weights Curb Weight Min: Approx. 1200 kg (2646 lbs) Gross Vehicle Weight Rating Gvw: Varies by model and configuration, typically around 1700-1800 kg Cargo Cargo Volume Sedan: Approximately 450 liters (15.9 cu ft) Cargo Volume Hatchback: Approximately 360 liters (12.7 cu ft) with seats up, expandable significantly with seats folded 🛡️ Safety Features Ratings Euro Ncap Rating: No official Euro NCAP ratings publicly available for this specific generation and region. Active Features ABS: Optional on some trims, standard on higher specifications later in the model run Traction Control: Rarely available, not a common feature for this era Passive Features Airbags Driver: Standard on most trims Airbags Passenger: Optional or standard on higher trims Seatbelts: 3-point seatbelts with pre-tensioners for front occupants Child Seat Anchors: ISOFIX points were not standard in this period for this model 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player with optional CD player. Basic speaker configurations. Dashboard Display: Analog gauges for speedometer, tachometer, fuel, and temperature. Warning lights for various systems. Driver Assistance Cruise Control: Available on higher trim levels. Connectivity Phone Integration: No factory Bluetooth or smartphone integration. Aftermarket solutions typically required....
4-speed Automatic (INVECS-II with adaptive shift logic)
Transmission Type Diesel:
5-speed Manual
Features
Clutch Type:
Hydraulically actuated dry single plate clutch
Fluid Specs
Manual Transmission Fluid Type:
API GL-4 SAE 75W-90 or SAE 75W-85
Automatic Transmission Fluid Type:
Diamond ATF SP-II M or equivalent
📐 Dimensions
Exterior Sedan
Length:
Approx. 4435 mm (174.6 in)
Width:
Approx. 1745 mm (68.7 in)
Height:
Approx. 1415 mm (55.7 in)
Exterior Hatchback
Length:
Approx. 4315 mm (169.9 in)
Width:
Approx. 1745 mm (68.7 in)
Height:
Approx. 1425 mm (56.1 in)
Wheelbase
Wheelbase:
Approx. 2600 mm (102.4 in)
Weights
Curb Weight Min:
Approx. 1200 kg (2646 lbs)
Gross Vehicle Weight Rating Gvw:
Varies by model and configuration, typically around 1700-1800 kg
Cargo
Cargo Volume Sedan:
Approximately 450 liters (15.9 cu ft)
Cargo Volume Hatchback:
Approximately 360 liters (12.7 cu ft) with seats up, expandable significantly with seats folded
🛡️ Safety Features
Ratings
Euro Ncap Rating:
No official Euro NCAP ratings publicly available for this specific generation and region.
Active Features
ABS:
Optional on some trims, standard on higher specifications later in the model run
Traction Control:
Rarely available, not a common feature for this era
Passive Features
Airbags Driver:
Standard on most trims
Airbags Passenger:
Optional or standard on higher trims
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants
Child Seat Anchors:
ISOFIX points were not standard in this period for this model
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player with optional CD player. Basic speaker configurations.
Dashboard Display:
Analog gauges for speedometer, tachometer, fuel, and temperature. Warning lights for various systems.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Phone Integration:
No factory Bluetooth or smartphone integration. Aftermarket solutions typically required.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change Interval:
Every 15,000 km (9,300 miles) or 12 months, whichever comes first (under normal driving conditions).
Service Intervals Filters
Oil Filter Replacement:
Replace with every oil change.
Air Filter Replacement:
Every 30,000 km (18,600 miles) or 24 months.
Fuel Filter Replacement:
Every 60,000 km (37,000 miles) or 48 months.
Service Intervals Timing
Timing Belt Replacement:
Every 90,000 km (56,000 miles) or 6 years, whichever comes first. Crucial for preventing catastrophic engine damage.
Fluid Specifications
Engine Oil Specification:
API SG or SH, ACEA A2-96, SAE 10W-40 (preferred) or 10W-30. Check manual for specific conditions.
Coolant Specification:
Mitsubishi Genuine Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Mix 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Common Complaint Ignition Coils:
Intermittent misfires, rough idling, check engine light due to failing ignition coils (especially on 1.6L engines).
Common Complaint Suspension Bushings:
Wear and tear on suspension bushings (front and rear) leading to knocking noises and poor handling.
Common Complaint ABS Sensors:
ABS warning light illumination due to faulty ABS wheel speed sensors.
Common Complaint Rust:
Prone to rust in areas with harsh winters, particularly around wheel arches, sills, and subframes.
Common Complaint Exhaust System:
Corrosion and failure of exhaust components (muffler, pipes) over time.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation
Brand Focus:
Known for reliable engineering and often innovative features, particularly in SUVs and performance cars.
Model Evolution
Predecessor:
Mitsubishi Lancer (shared some underpinnings with earlier Lancers)
Successor:
Mitsubishi Lancer (new generation)
Development Collaboration:
Developed in conjunction with Volvo (for the European market, leading to the Volvo S40/V40 and Mitsubishi Carisma being built on a shared platform in the Netherlands).
Production
Manufacturing Location:
Born, Netherlands (NedCar plant)
Production Years:
1995-2004 (first generation)
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