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1996-2003 Mitsubishi Carisma Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Carisma Generation: DA1A/DA2A/DA5A/DA6A Codes Chassis Codes: DA1A, DA2A, DA5A, DA6A 👋 Introduction Market Position Segment: Compact family car, C-segment. Target Audience: Families, commuters...
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Type: Car
Vendor:
Sku: 585937
1996-2003 Mitsubishi Carisma Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Carisma
Generation:
DA1A/DA2A/DA5A/DA6A
Codes
Chassis Codes:
DA1A, DA2A, DA5A, DA6A
👋 Introduction
Market Position
Segment:
Compact family car, C-segment.
Target Audience:
Families, commuters seeking practical and reliable transportation.
Competitive Analysis
Key Competitors:
Ford Focus, Opel/Vauxhall Astra, Volkswagen Golf, Renault Megane, Peugeot 306, Toyota Corolla, Nissan Almera.
Key Features
Design Philosophy:
Emphasis on comfort, practicality, and value for money, with a distinctive styling for its era.
Platform Sharing:
Shared platform with the Mitsubishi Space Star (later Mitsubishi Colt Plus in some markets) and was also rebadged as the Proton Wira in some regions.
📋 Manual Details
Coverage Areas
Vehicle Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Regions Covered:
Global (primarily Europe, Asia)
Page Count
Estimated Page Count:
Varies by specific edition, but typically 1000+ pages for comprehensive service manuals.
Manual Type
Type:
Workshop Service Repair Manual (WSRM)
Language
Language:
English
Format
Format:
Digital (likely PDF)
File Format Quality:
High-resolution digital scans, typically searchable PDF with clear imagery and text.
Printability:
Printable pages for on-the-go use in a workshop environment.
Completeness
Completeness Level:
Full workshop manual, intended for dealership technicians and experienced DIY mechanics.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhauls, component identification, timing belt/chain, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system.
Fuel System:
Fuel injection system, fuel pump, injectors, fuel filter, fuel tank, evaporative emission control (EVAP).
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), ignition timing, ECU control.
Emission Control:
Catalytic converter, oxygen sensors, EGR system, PCV system, diagnostic trouble codes (DTCs) related to emissions.
Transmission Manual:
Clutch system, gearbox overhaul, gear selection mechanism, linkages, internal components, lubrication.
Transmission Automatic:
Automatic transmission overhaul, hydraulic control system, torque converter, solenoids, gear shifting, fluid and filter replacement, diagnostic procedures.
Drivetrain Axles:
Front and rear drive shafts, CV joints, differential, wheel bearings, hub assemblies.
Suspension Front:
MacPherson struts, control arms, ball joints, bushings, sway bar, steering knuckle, alignment specifications.
Suspension Rear:
Multi-link, torsion beam, shock absorbers, springs, control arms, bushings, alignment specifications.
Steering System:
Power steering pump, steering rack, tie rod ends, steering column, column lock, alignment.
Brake System:
Front and rear disc brakes, brake pads, rotors, calipers, brake lines, master cylinder, brake booster, parking brake, ABS system diagnostics.
Electrical System:
Battery, alternator, starter motor, fuses, relays, wiring diagrams, lighting system, horn, power windows, power mirrors, central locking.
Body Exterior:
Body panel removal and installation (hood, doors, fenders, bumpers), glass replacement, door hardware, hinges, locks, exterior trim.
Body Interior:
Dashboard removal and installation, seats, trim panels, carpeting, headliner, airbags (handling and safety precautions).
HVAC System:
Air conditioning system, heater core, blower motor, refrigerant handling, diagnostic and repair procedures.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, fluid checks, inspections, and component replacements (e.g., timing belt).
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults across all vehicle systems, including symptom-based troubleshooting guides.
Repair Procedures:
Comprehensive instructions for disassembly, repair, and reassembly of all major and minor components, including torque specifications and critical clearances.
Wiring Diagrams:
Complete and detailed electrical system wiring diagrams for all circuits, allowing for precise diagnosis and repair of electrical faults.
Diagnostic Procedures:
On-board diagnostics (OBD-I/OBD-II) information, diagnostic trouble code (DTC) lookup and interpretation, scan tool usage recommendations.
Specifications Data:
All critical technical specifications, including torque values, clearances, fluid capacities, pressures, electrical resistances, and performance data.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics and bodywork repairs.
Diagnostic Capability:
Advanced diagnostic procedures for engine management, ABS, airbags, and transmission control modules.
⚙️ Engine Specifications
Primary Engine
Engine Code Examples:
4G13, 4G14, 4G15, 4G92, 4G93
Displacement Range:
1.3L to 2.0L
Performance
Horsepower Range:
Approximately 75 PS (55 kW) to 140 PS (103 kW), depending on engine variant and tuning.
Torque Range:
Approximately 110 Nm to 180 Nm.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injection.
Fuel Type:
Unleaded gasoline.
Engine Layout
Layout:
Inline 4-cylinder, transversely mounted.
Valve Train:
SOHC or DOHC (depending on engine variant), with timing belt or chain.
🔧 Transmission
Standard
Transmission Type Standard:
5-speed manual transmission.
Optional
Transmission Type Optional:
4-speed automatic transmission.
Features
Drive Type:
Front-wheel drive (FWD).
📐 Dimensions
Exterior
Length:
Approx. 4300 mm (169.3 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1430 mm (56.3 in)
Wheelbase:
Approx. 2500 mm (98.4 in)
Weights
Curb Weight:
Approx. 1150 - 1300 kg (2535 - 2866 lbs), depending on specification.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Early models (pre-2000) generally received lower ratings. Later models and updates may vary. Specific ratings should be verified for individual markets.
Active Features
ABS:
Available on higher trim levels and later models.
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional or standard on later models/trims.
Seatbelts:
Pre-tensioner seatbelts for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player. Often basic by modern standards, with few advanced features.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 12 months, whichever comes first (check manual for exact interval and oil type).
Timing Belt Replacement:
Crucial maintenance item. Typically recommended every 90,000 - 120,000 km (56,000 - 75,000 miles) or 5-7 years for most engine variants. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or ACEA A2/A3; viscosity typically 5W-30, 10W-40, or 15W-40 depending on climate. Refer to manual for exact specification.
Coolant:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Mitsubishi DiaQueen Super Long Life Coolant (SLLC) is often recommended.
Brake Fluid:
DOT 3 or DOT 4. Must be replaced periodically (e.g., every 2 years).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil. Capacity approx. 2.0-2.5 liters.
Transmission Fluid Automatic:
Mitsubishi ATF SP-II, SP-III or equivalent. Capacity approx. 4.5-5.5 liters for torque converter drain and fill.
Known Issues
Engine Mounts:
Can wear out, leading to excessive vibration.
Suspension Bushings:
Wear and tear on control arm bushings and other suspension components is common, leading to knocking noises and poor handling.
Window Regulators:
Electric window mechanisms can be prone to failure.
Rust Corrosion:
Common on wheel arches, sills, and subframes, especially in areas with road salt.
Ignition Coil Packs:
Can fail, leading to misfires and rough running, particularly on the GDI variants if equipped.
Door Lock Actuators:
Can fail, causing issues with central locking.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Mitsubishi Motors, a Japanese automotive manufacturer with a long history of producing reliable and durable vehicles across various segments.
Model Evolution
First Generation:
Introduced in 1996 as a replacement for the Lancer in European markets and as a new model elsewhere. Designed with European market preferences in mind.
Facelift:
Received a significant facelift around 1999/2000, with updated styling, improved interior materials, and revised engine options.
Production
Production Period:
1996-2003.
Manufacturing Locations:
Primarily manufactured in the Netherlands (NedCar) for the European market, and also in Japan.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While not a multiple award winner, it was generally well-received for its practicality and value in its segment during its production run. Specific awards are not widely documented.
Ratings
Reliability Perception:
Generally considered a reliable car if properly maintained, though some electrical components and older mechanical parts can be subject to wear.
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