Mitsubishi Carisma 1996 1997 1998 1999 -2003 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Carisma Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Chassis Codes: DA1A, DA2A, DA5A, DA6A Codes Platform: Mitsubishi Space Star/Carisma platform (shared with Volvo S40/V40) 👋 Introduction Market Position Segment: Compact family car Target Audience: Families, commuters seeking practicality and reliability Competitive Analysis Key Competitors: Ford Focus, Volkswagen Golf, Vauxhall/Opel Astra, Peugeot 306, Renault Mégane Key Features Design Philosophy: European design influence (collaboration with Netherlands Design Centre), emphasis on comfort and practicality. Platform Sharing: Shared platform with Volvo S40/V40, indicating robust engineering and safety focus. 📋 Manual Details Coverage Areas Manual Type: Official Factory Service Repair Shop Manual Language: English Format: Digital PDF Download Page Count Estimated Page Count: Varies by specific engine/transmission, but typically over 1000 pages for a comprehensive factory manual 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, repair of all engine components (pistons, rings, bearings, crankshaft, camshaft, valves, timing system) Engine Management: Fuel injection systems, ignition systems, emissions control systems, sensors, actuators, ECU diagnostics Transmission Manual: Clutch, gearbox disassembly, assembly, repair, shift mechanism Transmission Automatic: Automatic transmission disassembly, assembly, repair, hydraulic control, torque converter Suspension: Front and rear suspension components, struts, shocks, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, steering column Brakes: Hydraulic system, ABS (if equipped), brake pads, rotors, calipers, lines, bleeding procedures Electrical System: Wiring diagrams, component locations, fuse/relay box diagrams, starter, alternator, battery, lighting, accessories Body And Chassis: Body panel removal/installation, interior trim, glass, doors, bumpers, chassis structural information Heating Ventilation And Air Conditioning: HVAC system components, refrigerant, diagnosis, repair Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection Troubleshooting: Diagnostic procedures for common issues, fault codes, symptom-based troubleshooting Engine Rebuild: Detailed steps for major engine overhaul and component replacement Transmission Overhaul: Comprehensive procedures for rebuilding both manual and automatic transmissions Brake System Repair: Component replacement, bleeding, ABS diagnostics Electrical Component Replacement: Diagnosing and replacing electrical parts like sensors, actuators, and modules Bodywork And Collision Repair: Information on body panel alignment and repair Suspension And Steering Repair: Replacement of ball joints, tie rods, shocks, struts Technical Depth Depth Of Information: Comprehensive: Covers everything from basic maintenance to complete rebuilds and advanced diagnostics. Oem Specifications: Includes torque specifications, fuel pressure charts, electrical data, compression ranges, tolerances, OEM part number references, paint codes. Diagrams And Illustrations: Features exploded diagrams, charts, and photographs to aid in disassembly and reassembly. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically searchable PDF text Print Quality Printable: Yes Print Format: Printable page-by-page for taking to service locations or for reference Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Codes: 4G92 (1.6L), 4G93 (1.8L SOHC/DOHC), 4G63 (2.0L DOHC), 6A12 (2.5L V6) 1.6L (4G92) Specs: Approx. 90-100 hp, 1.6-liter inline-4, SOHC 1.8L (4G93) Specs: Approx. 113-125 hp (SOHC), 140 hp (DOHC GDI), 1.8-liter inline-4 2.0L (4G63) Specs: Approx. 130-150 hp, 2.0-liter inline-4, DOHC 2.5L V6 (6A12) Specs: Approx. 160-170 hp, 2.5-liter V6, SOHC Performance Fuel Delivery: Multi-point Fuel Injection (MPI), Gasoline Direct Injection (GDI) on some 1.8L models Fuel Type: Unleaded gasoline Fuel System Fuel Pressure: Specific values provided in manual (e.g., ~3 bar for MPI systems) 🔧 Transmission Standard Gearbox Options: 5-speed manual, 4-speed automatic Optional Transmission Type: 4-speed INVECS-II automatic transmission Features Manual Transmission Fluid: API GL-3 or GL-4, SAE 75W-90 or 80W-90 (specific part numbers in manual) Automatic Transmission Fluid: DIA Queen ATF-SP II M or equivalent (specific part numbers in manual) 📐 Dimensions Exterior Length: Approximately 4510 mm (177.6 in) for sedan, 4350 mm (171.3 in) for hatchback Width: Approximately 1730 mm (68.1 in) Height: Approximately 1405-1430 mm (55.3-56.3 in) Weights Curb Weight: Approximately 1100-1350 kg (2425-2976 lbs) depending on engine and equipment Gross Vehicle Weight Rating: Specific values vary by model and are detailed in the manual 🛡️ Safety Features Ratings Euro Ncap Rating: Achieved 3 stars in 1997 Euro NCAP testing (for the sedan variant). Active Features ABS: Available as an option on many models. Passive Features Airbags: Driver and passenger airbags available, side airbags optional on some later models. Seatbelts: Pre-tensioning front seatbelts 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, often with speakers in front and rear doors. Climate Control: Manual or automatic climate control available on higher trims. Driver Assistance Cruise Control: Available on some models and trims. Connectivity Parking Sensors: Not a standard feature, but aftermarket options were common. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles or 12 months, or as per manufacturer recommendations in the manual. Timing Belt Replacement: Crucial for non-interference engines. Interval typically around 60,000-90,000 miles or 5-7 years. Specifics for each engine variant are in the manual. Fluid Specifications Engine Oil...
Approx. 113-125 hp (SOHC), 140 hp (DOHC GDI), 1.8-liter inline-4
2.0L (4G63) Specs:
Approx. 130-150 hp, 2.0-liter inline-4, DOHC
2.5L V6 (6A12) Specs:
Approx. 160-170 hp, 2.5-liter V6, SOHC
Performance
Fuel Delivery:
Multi-point Fuel Injection (MPI), Gasoline Direct Injection (GDI) on some 1.8L models
Fuel Type:
Unleaded gasoline
Fuel System
Fuel Pressure:
Specific values provided in manual (e.g., ~3 bar for MPI systems)
🔧 Transmission
Standard
Gearbox Options:
5-speed manual, 4-speed automatic
Optional
Transmission Type:
4-speed INVECS-II automatic transmission
Features
Manual Transmission Fluid:
API GL-3 or GL-4, SAE 75W-90 or 80W-90 (specific part numbers in manual)
Automatic Transmission Fluid:
DIA Queen ATF-SP II M or equivalent (specific part numbers in manual)
📐 Dimensions
Exterior
Length:
Approximately 4510 mm (177.6 in) for sedan, 4350 mm (171.3 in) for hatchback
Width:
Approximately 1730 mm (68.1 in)
Height:
Approximately 1405-1430 mm (55.3-56.3 in)
Weights
Curb Weight:
Approximately 1100-1350 kg (2425-2976 lbs) depending on engine and equipment
Gross Vehicle Weight Rating:
Specific values vary by model and are detailed in the manual
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Achieved 3 stars in 1997 Euro NCAP testing (for the sedan variant).
Active Features
ABS:
Available as an option on many models.
Passive Features
Airbags:
Driver and passenger airbags available, side airbags optional on some later models.
Seatbelts:
Pre-tensioning front seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, often with speakers in front and rear doors.
Climate Control:
Manual or automatic climate control available on higher trims.
Driver Assistance
Cruise Control:
Available on some models and trims.
Connectivity
Parking Sensors:
Not a standard feature, but aftermarket options were common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or 12 months, or as per manufacturer recommendations in the manual.
Timing Belt Replacement:
Crucial for non-interference engines. Interval typically around 60,000-90,000 miles or 5-7 years. Specifics for each engine variant are in the manual.
Fluid Specifications
Engine Oil Type:
API SJ or higher, viscosity typically 10W-40 or 5W-30 (refer to manual for specific engine and climate recommendations).
Coolant:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for exact specification).
Known Issues
Common Problems:
Early models could experience some electrical gremlins, exhaust manifold cracks on some 1.8L models, and wear on suspension bushings. Clutch wear on manual transmissions.
Engine Specific Notes:
4G93 GDI engines may require specific maintenance due to direct injection technology.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history of innovation and diverse vehicle production.
Model Evolution
Carisma Development:
Developed in collaboration with Volvo, sharing the platform with the Volvo S40/V40. Designed with a focus on European market tastes and standards.
Production
Production Period:
1995-2005 (Globally), with this manual covering 1996-2003.
Manufacturing Locations:
Primarily produced in Born, Netherlands (NedCar factory), and also in Japan.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While not receiving specific major 'awards' in the traditional sense, the Carisma was generally well-regarded for its practicality, comfort, and value for money in its segment.
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