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1995-2000 Mitsubishi Carisma Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Carisma Model Years Covered: 1995, 1996, 1997, 1998, 1999, 2000 Codes Internal Model Code: DA1A (sedan), DA2A (hatchback) 👋 Introduction Market Position Segment:...
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Type: Car
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Sku: 585963
1995-2000 Mitsubishi Carisma Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Carisma
Model Years Covered:
1995, 1996, 1997, 1998, 1999, 2000
Codes
Internal Model Code:
DA1A (sedan), DA2A (hatchback)
👋 Introduction
Market Position
Segment:
Compact family car, often competing in the European C-segment
Target Audience:
Families and individuals seeking reliable, practical, and affordable transportation
Competitive Analysis
Key Competitors:
Ford Focus, Volkswagen Golf, Opel Astra, Peugeot 306, Toyota Corolla
Key Features
Design Philosophy:
Practicality, comfort, and value for money, often with distinctive styling by Dutch designer John L. K. Hansen
Platform:
Shared platform with the Mitsubishi Space Star (later models) and Colt, some underpinning shared with Hyundai Lantra
Body Styles:
Offered as both a 4-door sedan and a 5-door hatchback
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive factory service and repair
Secondary Coverage:
Maintenance, diagnostics, troubleshooting, wiring diagrams, specifications
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
File Format:
PDF
Searchability:
Fully searchable text for quick information retrieval
Printability:
Printable pages for workshop use
Digital Features:
Hyperlinked table of contents and cross-references
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, assembly, overhaul, timing belt, seals, gaskets, pistons, rings, crankshaft, camshafts, valves
Engine Management:
ECU diagnosis, fuel injection (MPI), ignition system, sensors (MAP, TPS, O2, CKP, CMP), emissions control, OBD-I/OBD-II troubleshooting
Transmission Manual:
Clutch system, gearbox overhaul, gear selection, bearings, seals, maintenance
Transmission Automatic:
ATF specifications, torque converter, hydraulic control, valve body, planetary gears, seals, maintenance, diagnostic procedures
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, control arms, ball joints, steering rack, power steering system, alignment specifications
Brakes:
Brake fluid specifications, ABS system (if equipped), hydraulic lines, calipers, pads, rotors, parking brake, bleeding procedures, troubleshooting
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, instruments, switches, fuses, relays, body control modules, HVAC controls
Body And Chassis:
Body panel removal and installation, door mechanisms, glass, trim, underbody coatings, rust prevention, structural components
HVAC System:
Air conditioning (refrigerant type, charging), heating system, blower motor, controls, diagnostics
Fuel System:
Fuel pump, fuel filter, injectors, fuel lines, fuel tank, evaporative emission control (EVAP)
Cooling System:
Radiator, coolant specifications, water pump, thermostat, hoses, fan operation, troubleshooting
Manual Coverage
Procedures Included:
Routine maintenance, scheduled servicing, component replacement, system diagnostics, troubleshooting flowcharts, wiring diagram interpretation
Procedures Included
Repair Procedures:
Step-by-step guides for common and complex repairs, torque specifications for all fasteners
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based diagnostics, common failure points and solutions
Wiring Diagrams:
Detailed electrical schematics for all major systems, component locations
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and experienced DIYers
Diagnostic Capability:
Includes diagnostic procedures and specifications for various electronic control units (ECUs)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G92
Engine Type:
Inline 4-cylinder, SOHC/DOHC
Displacement:
1.8 Liters (1834 cc)
Bore X Stroke:
81.0 mm x 89.2 mm
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower Est:
115-125 PS (85-93 kW) for SOHC, 130-145 PS (96-107 kW) for DOHC GDI variants
Torque Est:
160-180 Nm (118-133 lb-ft) (depending on variant)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) / Gasoline Direct Injection (GDI) on some later variants
Fuel Type:
Unleaded Gasoline
Engine Variations
Other Engines:
1.3L (4G13) SOHC, 1.6L (4G92) SOHC MPI, 2.0L (4G94) DOHC GDI, 1.9L (F4A8) Turbo Diesel (less common)
Technical Specs
Timing Belt Replacement Interval:
Typically 90,000 km or 5 years (refer to manual for exact vehicle)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (INVECS-II)
Features
Manual Transmission Codes:
W5MG1 (for 1.8L)
Automatic Transmission Codes:
F4A23
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 (check manual for exact grade)
Automatic Transmission Fluid Type:
DIA Queen ATF-SP II (or equivalent, check manual)
📐 Dimensions
Exterior
Length Sedan:
Approx. 4470 mm (176 in)
Length Hatchback:
Approx. 4300 mm (169 in)
Width:
Approx. 1740 mm (68.5 in)
Height:
Approx. 1420 mm (55.9 in)
Wheelbase:
Approx. 2620 mm (103.1 in)
Weights
Curb Weight:
Approx. 1200-1300 kg (2645-2866 lbs) (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Refer to vehicle compliance plate
Cargo
Trunk Volume Sedan:
Approx. 440 liters (15.5 cu ft)
Cargo Volume Hatchback:
Approx. 370 liters (13.1 cu ft) (seats up)
🛡️ Safety Features
Ratings
Euro Ncap Rating Early:
3 Stars (for early models, testing standards have evolved)
Active Features
ABS:
Optional on most models, standard on higher trims or later years
Traction Control:
Rarely equipped, mostly on sportier or later models
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional/standard on higher trims
Seatbelts:
Pre-tensioning front seatbelts
Child Seat Anchors:
ISOFIX not common on early models, likely standard on later years
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, optional CD player. Basic speaker setup.
Dashboard Features:
Analog gauges for speedometer, tachometer, fuel, and temperature. Basic trip computer on some trims.
Driver Assistance
Cruise Control:
Optional on higher specification models.
Connectivity
Aux Input:
Not standard; aftermarket solutions required for modern device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
15,000 km or 12 months (whichever comes first), using synthetic oil (refer to manual for exact interval and oil type).
Air Filter Replacement Interval:
Every 30,000 km or 24 months
Fuel Filter Replacement Interval:
Every 60,000 km (for petrol engines)
Fluid Specifications
Engine Oil Type:
API SJ/SL, ILSAC GF-3, SAE 5W-30 or 10W-40 (refer to manual based on climate and specific engine)
Coolant Type:
Ethylene Glycol based coolant, typically a pink or orange type (e.g., Mitsubishi Super Long Life Coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine:
Timing belt failure if not replaced on schedule (non-interference engine can be an advantage), potential for minor oil leaks from seals.
Electrical:
Occasional issues with window regulators, central locking actuators, and dashboard warning lights.
Body Corrosion:
Rust can be a concern in areas with heavy road salt usage, especially around wheel arches and sills.
Suspension:
Wear in front control arm bushings and ball joints over time.
Technical Tips
Spark Plugs:
NGK BKR5EKUC (or equivalent platinum/iridium for longer life)
Tire Sizes:
Common sizes include 185/65 R14, 195/60 R15, 205/50 R16 (check manual for specific trim)
Wheel Bolt Pattern:
4x114.3 mm (4.5 inch)
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, Japan
Model Evolution
Introduction Year:
1995
Redesign Cycle:
First generation (1995-2000). A facelift occurred around 1998/1999.
Discontinuation:
Replaced by the Mitsubishi Lancer (in some markets) and the second-generation Space Star/Colt.
Production
Manufacturing Location:
Bornem, Belgium (primarily for European markets); also produced in Japan and possibly other locations.
Production Volume:
Significant volume for the European market, though not a global bestseller.
🏆 Awards & Recognition
Recognitions
European Market Reception:
Generally well-received for its practicality and value, but often struggled to match the refinement and perceived quality of German rivals.
Ratings
Owner Satisfaction General:
Mixed, with strong points in reliability for some owners, but occasional criticism of interior materials and ride comfort.
Certifications
Emissions Standards:
Compliant with European emissions standards of the period (Euro 2/3).
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