Mitsubishi Space Star Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003 2004 2005
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🏷️ Basic Information Identification Make: Mitsubishi Model: Space Star Common Name: Mitsubishi Space Wagon (some markets) Generation Generation Designation: First Generation Generation Years: 1998-2005 (for this manual's coverage) Codes Chassis Code Prefix: DG 👋 Introduction Market Position Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families and individuals seeking practical, versatile, and affordable transportation Competitive Analysis Key Competitors: Opel/Vauxhall Zafira, Ford Focus C-Max, Renault Scénic, Volkswagen Golf SV/Touran Key Features Design Philosophy: Maximizing interior space and practicality within a compact footprint, often with a distinctive, somewhat boxy but functional design. Versatility: Flexible seating arrangements, ample storage solutions, and a raised driving position contributing to its MPV designation. Manual Purpose Utility: Essential for DIY mechanics, fleet maintenance, and professional workshops seeking accurate repair and diagnostic information. 📋 Manual Details Coverage Areas Region Of Origin: Likely European Market Focus (due to model name and year range) Country Of Manufacture: Japan and Netherlands (for European market variants) Page Count Estimated Page Count: Over 1000 pages (typical for a comprehensive workshop manual) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system Transmission: Manual and Automatic Transmission repair, overhaul, and troubleshooting Drivetrain: Clutch, axles, drive shafts, differentials Suspension: Front and rear suspension components, steering system, wheel alignment Brakes: Brake system diagnostics, repair, ABS (Anti-lock Braking System) components Electrical: Wiring diagrams, lighting, starting and charging system, instrumentation, power accessories, body electronics, ECU diagnostics Bodywork: Body panel repair, interior trim removal and installation, glass replacement, doors, tailgate, bumpers HVAC: Heating, Ventilation, and Air Conditioning system service and repair Diagnostic Troubleshooting: Diagnostic trouble codes (DTCs), fault finding procedures, symptom-based troubleshooting Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, belt adjustments, fluid checks Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper rebuilding Diagnostics: Step-by-step diagnostic procedures for various systems Component Replacement: Detailed instructions for replacing common and complex components Electrical Troubleshooting: Wire tracing, connector diagnosis, component testing Technical Specifications: Torque specifications, clearances, timing settings, fluid capacities, pressure readings Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and bodywork. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (typically) Print Quality Print Readability: High-resolution scans ensuring clear diagrams and text for printing Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Common: 4G9 Series (e.g., 4G92, 4G93) Engine Configuration: Inline 4-cylinder Displacement Common: 1.3L (1300cc), 1.6L (1600cc), 1.8L (1800cc) Fuel Delivery: Multi-point Fuel Injection (MPI) Valve Train: SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) Performance Horsepower Range Typical: Approximately 75 hp to 125 hp depending on engine size and variant Torque Range Typical: Approximately 110 Nm to 170 Nm depending on engine size and variant Fuel System Fuel Type: Unleaded Petrol (Gasoline) Fuel Octane Rating Minimum: 91 RON (Research Octane Number) recommended Engine Management ECU Type: Proprietary Mitsubishi Engine Control Unit (ECU), specific models detailed in manual 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (INVECS-II system often used) Features Clutch Type: Dry, single-plate clutch (for manual transmission) Automatic Transmission Modes: May include Power and Snow modes for adaptive shifting Fluid Specification Manual Transmission Fluid: API GL-4, SAE 75W-90 (or as specified by Mitsubishi) Automatic Transmission Fluid: Mitsubishi ATF SP-II or SP-III equivalent 📐 Dimensions Exterior Length Mm: Approx. 4200-4300 mm Width Mm: Approx. 1690-1700 mm Height Mm: Approx. 1610-1640 mm Wheelbase Mm: Approx. 2600-2630 mm Interior Seating Capacity: 5 passengers (typical configuration, some variants might offer 7 seats) Cargo Volume Liters Min: Approx. 370-400 liters (with rear seats up) Cargo Cargo Volume Liters Max: Approx. 1500-1700 liters (with rear seats folded) Weights Curb Weight Kg Range: Approx. 1200-1350 kg Gross Vehicle Weight Rating Kg: Typically around 1800-1900 kg 🛡️ Safety Features Ratings Euro Ncap Rating Era: Likely 3 or 4 stars based on similar vehicles of the period; specific ratings may vary by test year and equipment. Active Features ABS: Standard on most trims from launch, optional on base models. Traction Control: Optional on higher trims or later models. Passive Features Airbags Standard: Driver and front passenger airbags (standard) Airbags Optional: Side airbags available on some higher-specification models Seatbelts: Three-point seatbelts with pretensioners for front seats Child Seat Anchors: ISOFIX mounting points often present 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, often with basic speaker configurations. Climate Control: Manual air conditioning (standard on many models), optional automatic climate control on higher trims. Driver Assistance Cruise Control: Available as an option on higher trim levels or with specific engine/transmission combinations. Connectivity Phone Integration: No factory integrated Bluetooth...
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and bodywork.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (typically)
Print Quality
Print Readability:
High-resolution scans ensuring clear diagrams and text for printing
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4G9 Series (e.g., 4G92, 4G93)
Engine Configuration:
Inline 4-cylinder
Displacement Common:
1.3L (1300cc), 1.6L (1600cc), 1.8L (1800cc)
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft)
Performance
Horsepower Range Typical:
Approximately 75 hp to 125 hp depending on engine size and variant
Torque Range Typical:
Approximately 110 Nm to 170 Nm depending on engine size and variant
Fuel System
Fuel Type:
Unleaded Petrol (Gasoline)
Fuel Octane Rating Minimum:
91 RON (Research Octane Number) recommended
Engine Management
ECU Type:
Proprietary Mitsubishi Engine Control Unit (ECU), specific models detailed in manual
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (INVECS-II system often used)
May include Power and Snow modes for adaptive shifting
Fluid Specification
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (or as specified by Mitsubishi)
Automatic Transmission Fluid:
Mitsubishi ATF SP-II or SP-III equivalent
📐 Dimensions
Exterior
Length Mm:
Approx. 4200-4300 mm
Width Mm:
Approx. 1690-1700 mm
Height Mm:
Approx. 1610-1640 mm
Wheelbase Mm:
Approx. 2600-2630 mm
Interior
Seating Capacity:
5 passengers (typical configuration, some variants might offer 7 seats)
Cargo Volume Liters Min:
Approx. 370-400 liters (with rear seats up)
Cargo
Cargo Volume Liters Max:
Approx. 1500-1700 liters (with rear seats folded)
Weights
Curb Weight Kg Range:
Approx. 1200-1350 kg
Gross Vehicle Weight Rating Kg:
Typically around 1800-1900 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating Era:
Likely 3 or 4 stars based on similar vehicles of the period; specific ratings may vary by test year and equipment.
Active Features
ABS:
Standard on most trims from launch, optional on base models.
Traction Control:
Optional on higher trims or later models.
Passive Features
Airbags Standard:
Driver and front passenger airbags (standard)
Airbags Optional:
Side airbags available on some higher-specification models
Seatbelts:
Three-point seatbelts with pretensioners for front seats
Child Seat Anchors:
ISOFIX mounting points often present
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, often with basic speaker configurations.
Climate Control:
Manual air conditioning (standard on many models), optional automatic climate control on higher trims.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels or with specific engine/transmission combinations.
Connectivity
Phone Integration:
No factory integrated Bluetooth or smartphone connectivity in this era; aftermarket solutions are common.
Lighting
Headlights:
Halogen headlights, often with manually adjustable beam height.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 15,000 km or 12 months, whichever comes first (or 7,500 km for severe conditions)
Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 30,000 km or 24 months
Spark Plug Replacement:
Every 60,000 km (for standard plugs), or 90,000 km (for platinum/iridium plugs if fitted)
Timing Belt Replacement:
Every 90,000 km or 5-7 years (critical maintenance item, often requires replacement of water pump and tensioner)
Fluid Specifications
Engine Oil Capacity Liters:
Approx. 3.5 - 4.0 liters (depending on engine)
Engine Oil Type Recommendation:
API SL/SM, ACEA A3/B3, SAE 5W-30 or 5W-40 (verify with manual for specific engine)
Coolant Type:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Problems Powertrain:
Timing belt failure (if not replaced on schedule), occasional oil leaks from seals, minor electronic sensor issues.
Common Problems Suspension Steering:
Worn front suspension bushings, premature wear of shock absorbers, potential play in steering rack.
Common Problems Electrical:
Instrument cluster failure (pixelation), issues with central locking actuators, minor wiring harness degradation in high-mileage vehicles.
Common Problems Body:
Rusting on wheel arches, sills, and tailgate seams, particularly in regions with road salt.
📚 Vehicle History
Brand Heritage
Manufacturer Focus:
Mitsubishi Motors Corporation, known for robust engineering and often sporty vehicles (like Lancer Evolution), but also practical family cars.
Model Evolution
Predecessor:
Evolved from the Mitsubishi Space Runner (also known as the RVR/Outlander in some markets), but the Space Star represented a distinct, larger design.
Platform Sharing:
Shares platform elements with other Mitsubishi models of the era, including the Carisma.
Production
Production Years Global:
1998-2005 (for this generation)
Manufacturing Locations:
Japan and Nedcar plant in Born, Netherlands (for European market models)
🏆 Awards & Recognition
Recognitions
European Design Awards:
While specific individual awards are not widely publicized for the Space Star, it was generally well-received for its practicality and interior packaging, contributing to Mitsubishi's strong presence in the European MPV market during its production run.
Ratings
Reliability Index:
Reliability varies by individual vehicle and maintenance history; early models of any manufacturer can have more teething issues. Comprehensive service is key.
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