Mitsubishi Carisma 1995-2003 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Carisma Production Years Covered: 1995-2003 Codes Platform Code: DA1A (sedan), DA2A (hatchback) 👋 Introduction Market Position Positioning: Compact family car designed for European markets, offering a balance of comfort, practicality, and value. Market Segment: Compact family car (C-segment) Competitive Analysis Competitors: Ford Focus, Opel Astra, Volkswagen Golf, Peugeot 306, Renault Mégane Key Features Design Philosophy: Developed in collaboration with Volvo, featuring a European design aesthetic and tailored driving characteristics for the target markets. Body Styles: Available as a 4-door sedan and a 5-door hatchback. 📋 Manual Details Coverage Areas Coverage: All models, engines, trim levels, and transmission types Regions: Primarily focused on European market specifications and configurations. Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Factory Service Repair Manual / Workshop Manual Content Type: Workshop Manual, Service Manual, Repair Manual, Maintenance Manual, Electrical Troubleshooting Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Service/Repair, Transmission Service/Repair, Fuel Injection/Fuel System, Cooling System, Emission System, Engine Control System Chassis: Brake System, Suspension, Steering, Chassis/Body, Differential/Drive, Axle Electrical And HVAC: Wiring Diagram, Electrical System, Heater/Air Conditioning Interior And Safety: Restraint System, Interior Bodywork: Chassis/Body, including exterior panels, interior trim, and body sealing. Fuel System Details: Fuel tank, fuel pump, fuel injectors, fuel lines, fuel filter. Exhaust System: Exhaust manifold, catalytic converter, muffler, pipes, and hangers. Procedures Included Maintenance: General Maintenance, Periodic Lubrication Diagnostics And Repair: Troubleshooting, Detailed substeps for repair procedures, Disassembly, Assembly, Cleaning, Reinstalling procedures Diagnostics: Troubleshooting guides for various systems, diagnostic trouble codes (DTCs) and their interpretations (where applicable for OBD-I/OBD-II systems). Overhaul: Detailed procedures for engine overhaul, transmission rebuilds, and component-level repairs. Recalibration: Procedures for recalibrating sensors and control modules as needed after repairs. Technical Depth Depth: Comprehensive, professional technician level, including diagnostics, repair, and maintenance Electrical Diagrams: Comprehensive wiring diagrams for all electrical systems, essential for diagnosing faults. 📊 Manual Specifications File Format Format: PDF Searchable Text: Likely searchable within PDF (typical for professional manuals) File Size: Not specified, but PDF manuals of this scope can range from tens to hundreds of megabytes. Print Quality Printability: Full Printable Viewing Features Zoom: Zoom IN/OUT capability Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Options: Diverse range including 1.3L, 1.6L (GDI and MPI), 1.8L (GDI and MPI), and 2.0L (GDI) gasoline engines, as well as 1.9L diesel and turbo-diesel engines. Specific Engines Covered: 4G13, 4G15 (MPI/GDI), 4G92 (MPI/GDI), 4G93 (MPI/GDI), 4G94 (GDI), 4D68 (Diesel/Turbo Diesel) Performance Typical Horsepower Range: Approximately 75 hp (1.3L) to 130 hp (2.0L GDI) for gasoline engines, and 70 hp (1.9L Diesel) to 90 hp (1.9L Turbo Diesel). Torque Specifications: Torque figures vary significantly by engine displacement and type; specific values are detailed within the manual. Fuel System Fuel Delivery: Multi-point fuel injection (MPI) and Gasoline Direct Injection (GDI) depending on engine variant. Fuel Type: Unleaded gasoline (petrol) for gasoline engines, Diesel fuel for diesel engines. 🔧 Transmission Standard Manual Transmission: Typically a 5-speed manual transmission. Optional Automatic Transmission: Optional 4-speed automatic transmission available on select models and engines. Features Drive Type: Front-wheel drive (FWD) only. Gear Ratios: Specific gear ratios for manual and automatic transmissions are provided for each model variant. 📐 Dimensions Exterior Wheelbase: Approximately 2600 mm (102.4 inches) Length: Approx. 4370 mm (172.0 inches) for sedan, 4280 mm (168.5 inches) for hatchback Weights Curb Weight: Varies by engine and trim, typically ranging from 1150 kg to 1350 kg (2535 lbs to 2976 lbs). 🛡️ Safety Features Ratings Euro Ncap Results: Tested by Euro NCAP, with results varying by year and test methodology. Typically achieved around 3-star ratings for adult occupant protection in early tests. Active Features Braking Systems: Available with Anti-lock Braking System (ABS) on higher trims and later models. Passive Features Airbags: Driver and front passenger airbags were standard or optional depending on market and trim level. Seat Belts: Pre-tensioning seat belts were often featured on front seats. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette players or CD players with basic speaker configurations. Higher trims may have upgraded sound systems. Display: Basic digital or analog displays for climate control and radio settings. Driver Assistance Cruise Control: Available as an option on higher trim levels. Connectivity Exterior Features: Body-coloured bumpers, door handles, and mirrors on higher trims; alloy wheels were optional. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using appropriate synthetic or semi-synthetic oil. Timing Belt Replacement: For 1.6L and 1.8L GDI/MPI engines, timing belt replacement is generally recommended every 90,000 km (56,000 miles)...
Troubleshooting guides for various systems, diagnostic trouble codes (DTCs) and their interpretations (where applicable for OBD-I/OBD-II systems).
Overhaul:
Detailed procedures for engine overhaul, transmission rebuilds, and component-level repairs.
Recalibration:
Procedures for recalibrating sensors and control modules as needed after repairs.
Technical Depth
Depth:
Comprehensive, professional technician level, including diagnostics, repair, and maintenance
Electrical Diagrams:
Comprehensive wiring diagrams for all electrical systems, essential for diagnosing faults.
📊 Manual Specifications
File Format
Format:
PDF
Searchable Text:
Likely searchable within PDF (typical for professional manuals)
File Size:
Not specified, but PDF manuals of this scope can range from tens to hundreds of megabytes.
Print Quality
Printability:
Full Printable
Viewing Features
Zoom:
Zoom IN/OUT capability
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Options:
Diverse range including 1.3L, 1.6L (GDI and MPI), 1.8L (GDI and MPI), and 2.0L (GDI) gasoline engines, as well as 1.9L diesel and turbo-diesel engines.
Approximately 75 hp (1.3L) to 130 hp (2.0L GDI) for gasoline engines, and 70 hp (1.9L Diesel) to 90 hp (1.9L Turbo Diesel).
Torque Specifications:
Torque figures vary significantly by engine displacement and type; specific values are detailed within the manual.
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) and Gasoline Direct Injection (GDI) depending on engine variant.
Fuel Type:
Unleaded gasoline (petrol) for gasoline engines, Diesel fuel for diesel engines.
🔧 Transmission
Standard
Manual Transmission:
Typically a 5-speed manual transmission.
Optional
Automatic Transmission:
Optional 4-speed automatic transmission available on select models and engines.
Features
Drive Type:
Front-wheel drive (FWD) only.
Gear Ratios:
Specific gear ratios for manual and automatic transmissions are provided for each model variant.
📐 Dimensions
Exterior
Wheelbase:
Approximately 2600 mm (102.4 inches)
Length:
Approx. 4370 mm (172.0 inches) for sedan, 4280 mm (168.5 inches) for hatchback
Weights
Curb Weight:
Varies by engine and trim, typically ranging from 1150 kg to 1350 kg (2535 lbs to 2976 lbs).
🛡️ Safety Features
Ratings
Euro Ncap Results:
Tested by Euro NCAP, with results varying by year and test methodology. Typically achieved around 3-star ratings for adult occupant protection in early tests.
Active Features
Braking Systems:
Available with Anti-lock Braking System (ABS) on higher trims and later models.
Passive Features
Airbags:
Driver and front passenger airbags were standard or optional depending on market and trim level.
Seat Belts:
Pre-tensioning seat belts were often featured on front seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette players or CD players with basic speaker configurations. Higher trims may have upgraded sound systems.
Display:
Basic digital or analog displays for climate control and radio settings.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels.
Connectivity
Exterior Features:
Body-coloured bumpers, door handles, and mirrors on higher trims; alloy wheels were optional.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first, using appropriate synthetic or semi-synthetic oil.
Timing Belt Replacement:
For 1.6L and 1.8L GDI/MPI engines, timing belt replacement is generally recommended every 90,000 km (56,000 miles) or 5 years.
Air Filter Replacement:
Recommended at 30,000 km (18,600 miles) or 24 months, or more frequently in dusty conditions.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 5W-30 or 10W-40 (check specific engine requirements in manual).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (SLLC) is often recommended for later models.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil (check manual for specific capacity).
Transmission Fluid Automatic:
Mitsubishi DiaQueen ATF-SPII or equivalent Dexron III compatible fluid.
Power Steering Fluid:
Dexron II or equivalent automatic transmission fluid is typically recommended.
Known Issues
Common Wear Items:
Catalytic converter issues, exhaust system corrosion, suspension component wear (bushings, ball joints), early GDI engine carbon buildup.
Electrical Problems:
Occasional issues with window regulators, central locking actuators, and dashboard warning lights.
Engine Management:
Idle speed control issues, lambda sensor failures, and ignition coil pack failures can occur.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation
Reputation:
Mitsubishi vehicles from this era are generally known for their reliability, though some models had specific issues that are well-documented and addressed in service manuals.
Collaboration:
Significant development collaboration with Volvo resulted in shared engineering and safety features.
Model Evolution
First Generation Introduction:
The Mitsubishi Carisma was introduced in 1995 as a replacement for the Lancer in the European market. It was developed in collaboration with Volvo, utilizing shared platforms and components. A facelift occurred in 1999, introducing revised styling and updated features.
Generation Details:
First generation (1995-2003) saw one major facelift in 1999. Engines and features evolved throughout its production run.
Production
Manufacturing Locations:
Primarily produced at Mitsubishi's NedCar plant in Born, Netherlands.