1999-2003 Mitsubishi Space Star Workshop Service Repair Manual 1999 2000 2001 2002 2003

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🏷️ Basic Information Identification Make: Mitsubishi Model: Space Star Generation Name: First Generation (Space Runner) Generation Code: DG0 Codes Model Years Covered: 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan. Target Audience: Families seeking a practical, versatile, and relatively affordable vehicle. Competitive Analysis Key Competitors: Renault Scénic, Ford C-Max, Volkswagen Golf SV (Sportsvan), Opel/Vauxhall Zafira. Key Features Body Style: Tall-boy design, sliding rear doors (on some configurations), flexible seating arrangements. Interior Versatility: Foldable/removable rear seats for maximizing cargo space. Engine Options: Typically offered with a range of gasoline engines, and potentially diesel engines in European markets. 📋 Manual Details Coverage Areas Primary Markets: Europe, Asia, Australia (often sold under different names like Mitsubishi Nimbus, Mitsubishi Chariot Grandis in some markets) Regions Of Focus: Technical procedures and specifications relevant to vehicles sold in the European market, which this manual is primarily targeted towards. Page Count Estimated Page Count: Approximately 1500+ pages (typical for a comprehensive workshop manual of this era) Manual Type Type: Workshop Service Repair Manual (WSRM) Primary Purpose: Detailed repair, maintenance, troubleshooting, and diagnostics for professional technicians and advanced DIY enthusiasts. Language Language: English Format Format: Digital (PDF) Searchability: Text-searchable PDF allowing for quick information retrieval. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, timing system (belt/chain), lubrication system. Engine Fuel System: Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, fuel lines, EVAP system. Engine Ignition System: Ignition coils, spark plugs, wiring, distributorless ignition system (DIS) components. Engine Cooling System: Radiator, fan, thermostat, water pump, coolant hoses, temperature sensors. Engine Emission Control: Exhaust manifold, catalytic converter, oxygen sensors (O2 sensors), EGR system (if applicable). Transmission Manual: Clutch operation, clutch assembly, gearbox disassembly/assembly, gear shift mechanism, final drive. Transmission Automatic: Automatic transmission operation, torque converter, valve body, transmission fluid cooler, hydraulic controls, electronic controls. Drivetrain Suspension: Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, wheel bearings. Drivetrain Axles: Front and rear drive axles, CV joints, propeller shafts (if AWD). Brakes System: Front and rear brake types (disc/drum), brake calipers, rotors, pads, master cylinder, brake lines, parking brake. Steering System: Power steering pump, rack and pinion, steering column, tie rods, steering linkage. Electrical System Battery: Battery testing, charging system, alternator, starter motor. Electrical System Lighting: Headlights, taillights, interior lighting, bulb replacement. Electrical System Instruments: Instrument cluster, gauges, warning lights, switches. Electrical System ECU: Engine Control Unit (ECU) diagnostics, sensor inputs/outputs, actuators. Body Interior: Dashboard removal, trim panels, seats, carpeting, headliner, door panels. Body Exterior: Doors, hood, trunk lid, fenders, bumpers, glass, mirrors, body panel repair. HVAC System: Air conditioning system, heater core, blower motor, climate controls, refrigerant recharge. Safety Systems: Airbag system diagnostics, SRS (Supplemental Restraint System) components. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement. Engine Repair: Complete engine overhaul, gasket replacement, valve adjustment, timing belt replacement procedures. Transmission Service: Transmission fluid and filter changes, clutch replacement, transmission repair (both manual and automatic). Brake System Repair: Brake pad/shoe replacement, rotor resurfacing/replacement, brake fluid bleeding, caliper/wheel cylinder repair. Suspension Steering Repair: Component replacement (struts, ball joints, tie rods), alignment specifications. Electrical Diagnostics: Wiring diagrams, troubleshooting flowcharts for electrical faults, component testing procedures. Bodywork Procedures: Door adjustment, panel replacement, seal replacement, bumper repair. Troubleshooting Guides: Diagnostic charts and tables for common symptoms and their likely causes. Diagnostic Trouble Codes: OBD-II codes (if applicable to specific models/years covered), interpretation, and diagnostic steps. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete component overhauls and complex diagnostics. Detail Level: Detailed step-by-step instructions, torque specifications, clearances, and assembly sequences. Wiring Diagrams: Detailed electrical schematics for various systems. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Delivery Format Consideration: Digital PDF allows for easy printing of specific sections or the entire manual. Paper Type Digital Format Consideration: Optimized for on-screen viewing and printing. ⚙️ Engine Specifications Primary Engine Engine Code Examples: 4G92, 4G93 (1.6L and 1.8L SOHC/DOHC MPI). Engine Type: Inline 4-cylinder, gasoline, Multi-Point Fuel Injection (MPI). Performance Displacement Common: 1597 cc (1.6L), 1834 cc (1.8L). Horsepower Range Typical: 90-125 hp (depending on engine variant and specific market). Torque Range Typical: 120-170 Nm (depending on engine variant). Fuel System Injection Type: Electronic Multi-Point Fuel Injection (MPI). Fuel Type: Unleaded gasoline (Octane rating as per market specifications, typically 91 RON). Timing Timing Belt Replacement Interval: Typically 90,000 - 100,000 km or 5-6 years, whichever comes first. Crucial to check manual for exact interval. 🔧 Transmission Standard Standard Transmission Type: 5-speed manual transmission. Optional Optional Transmission Type: 4-speed automatic transmission. Features Transmission Fluid Type Auto: Mitsubishi SP-III (or equivalent Dexron...

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Mots clés: 1999 2000 2001 2002 2003 Car Cars Mitsubishi Space Star

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Space Star

Generation Name:

First Generation (Space Runner)

Generation Code:

Codes

Model Years Covered:

1999, 2000, 2001, 2002, 2003

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan.

Target Audience:

Families seeking a practical, versatile, and relatively affordable vehicle.

Competitive Analysis

Key Competitors:

Renault Scénic, Ford C-Max, Volkswagen Golf SV (Sportsvan), Opel/Vauxhall Zafira.

Key Features

Body Style:

Tall-boy design, sliding rear doors (on some configurations), flexible seating arrangements.

Interior Versatility:

Foldable/removable rear seats for maximizing cargo space.

Engine Options:

Typically offered with a range of gasoline engines, and potentially diesel engines in European markets.

📋 Manual Details

Coverage Areas

Primary Markets:

Europe, Asia, Australia (often sold under different names like Mitsubishi Nimbus, Mitsubishi Chariot Grandis in some markets)

Regions Of Focus:

Technical procedures and specifications relevant to vehicles sold in the European market, which this manual is primarily targeted towards.

Page Count

Estimated Page Count:

Approximately 1500+ pages (typical for a comprehensive workshop manual of this era)

Manual Type

Type:

Workshop Service Repair Manual (WSRM)

Primary Purpose:

Detailed repair, maintenance, troubleshooting, and diagnostics for professional technicians and advanced DIY enthusiasts.

Language

Language:

English

Format

Format:

Digital (PDF)

Searchability:

Text-searchable PDF allowing for quick information retrieval.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, timing system (belt/chain), lubrication system.

Engine Fuel System:

Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, fuel lines, EVAP system.

Engine Ignition System:

Ignition coils, spark plugs, wiring, distributorless ignition system (DIS) components.

Engine Cooling System:

Radiator, fan, thermostat, water pump, coolant hoses, temperature sensors.

Engine Emission Control:

Exhaust manifold, catalytic converter, oxygen sensors (O2 sensors), EGR system (if applicable).

Transmission Manual:

Clutch operation, clutch assembly, gearbox disassembly/assembly, gear shift mechanism, final drive.

Transmission Automatic:

Automatic transmission operation, torque converter, valve body, transmission fluid cooler, hydraulic controls, electronic controls.

Drivetrain Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, springs, wheel bearings.

Drivetrain Axles:

Front and rear drive axles, CV joints, propeller shafts (if AWD).

Brakes System:

Front and rear brake types (disc/drum), brake calipers, rotors, pads, master cylinder, brake lines, parking brake.

Steering System:

Power steering pump, rack and pinion, steering column, tie rods, steering linkage.

Electrical System Battery:

Battery testing, charging system, alternator, starter motor.

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb replacement.

Electrical System Instruments:

Instrument cluster, gauges, warning lights, switches.

Electrical System ECU:

Engine Control Unit (ECU) diagnostics, sensor inputs/outputs, actuators.

Body Interior:

Dashboard removal, trim panels, seats, carpeting, headliner, door panels.

Body Exterior:

Doors, hood, trunk lid, fenders, bumpers, glass, mirrors, body panel repair.

HVAC System:

Air conditioning system, heater core, blower motor, climate controls, refrigerant recharge.

Safety Systems:

Airbag system diagnostics, SRS (Supplemental Restraint System) components.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement.

Engine Repair:

Complete engine overhaul, gasket replacement, valve adjustment, timing belt replacement procedures.

Transmission Service:

Transmission fluid and filter changes, clutch replacement, transmission repair (both manual and automatic).

Brake System Repair:

Brake pad/shoe replacement, rotor resurfacing/replacement, brake fluid bleeding, caliper/wheel cylinder repair.

Suspension Steering Repair:

Component replacement (struts, ball joints, tie rods), alignment specifications.

Electrical Diagnostics:

Wiring diagrams, troubleshooting flowcharts for electrical faults, component testing procedures.

Bodywork Procedures:

Door adjustment, panel replacement, seal replacement, bumper repair.

Troubleshooting Guides:

Diagnostic charts and tables for common symptoms and their likely causes.

Diagnostic Trouble Codes:

OBD-II codes (if applicable to specific models/years covered), interpretation, and diagnostic steps.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Technical Depth

Depth:

Comprehensive, covering everything from routine maintenance to complete component overhauls and complex diagnostics.

Detail Level:

Detailed step-by-step instructions, torque specifications, clearances, and assembly sequences.

Wiring Diagrams:

Detailed electrical schematics for various systems.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Delivery Format Consideration:

Digital PDF allows for easy printing of specific sections or the entire manual.

Paper Type

Digital Format Consideration:

Optimized for on-screen viewing and printing.

⚙️ Engine Specifications

Primary Engine

Engine Code Examples:

4G92, 4G93 (1.6L and 1.8L SOHC/DOHC MPI).

Engine Type:

Inline 4-cylinder, gasoline, Multi-Point Fuel Injection (MPI).

Performance

Displacement Common:

1597 cc (1.6L), 1834 cc (1.8L).

Horsepower Range Typical:

90-125 hp (depending on engine variant and specific market).

Torque Range Typical:

120-170 Nm (depending on engine variant).

Fuel System

Injection Type:

Electronic Multi-Point Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline (Octane rating as per market specifications, typically 91 RON).

Timing

Timing Belt Replacement Interval:

Typically 90,000 - 100,000 km or 5-6 years, whichever comes first. Crucial to check manual for exact interval.

🔧 Transmission

Standard

Standard Transmission Type:

5-speed manual transmission.

Optional

Optional Transmission Type:

4-speed automatic transmission.

Features

Transmission Fluid Type Auto:

Mitsubishi SP-III (or equivalent Dexron III/Mercon specification). Exact spec in manual.

Transmission Fluid Capacity Auto:

Approx. 6.0-7.0 Liters (check manual for precise capacity and fill procedure).

Transmission Fluid Type Manual:

GL-4 SAE 75W-90 or SAE 75W-85 gear oil. Exact spec in manual.

📐 Dimensions

Exterior

Length:

Approx. 4,370 mm (172.0 in)

Width:

Approx. 1,755 mm (69.1 in)

Height:

Approx. 1,640 mm (64.6 in)

Wheelbase:

Approx. 2,600 mm (102.4 in)

Weights

Curb Weight Range:

Approx. 1,250 kg - 1,400 kg (depending on engine and equipment).

🛡️ Safety Features

Ratings

Euro Ncap Rating:

3-star rating (for original European testing, may vary by specific test year and configuration).

Active Features

Optional/Standard depending on trim level and market.

Passive Features

Airbags:

Driver and front passenger airbags, potential for side airbags on higher trims.

Seatbelts:

Pre-tensioning seatbelts, ISOFIX child seat anchors (on rear seats).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player or CD player, with basic speaker system. Options for upgraded units with more speakers.

Climate Control:

Manual or semi-automatic climate control systems, depending on trim level.

Driver Assistance

Cruise Control:

Available as an option on some higher trim levels.

Parking Sensors:

Rarely factory fitted for this era, typically an aftermarket addition.

Connectivity

Connectivity Options:

Limited to basic radio/cassette/CD features. No integrated Bluetooth or USB for this generation.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 15,000 km or 12 months, whichever comes first (using synthetic or semi-synthetic oil).

Engine Oil Filter Replacement:

Replace at every oil change.

Air Filter Replacement:

Every 30,000 km or 24 months.

Cabin Air Filter Replacement:

Every 15,000 km or 12 months (if equipped).

Brake Fluid Change:

Every 2-3 years or 40,000 km, depending on moisture absorption.

Fluid Specifications

Engine Oil Specification:

API SG/SH or SJ, ACEA A1/A2/A3. Viscosity: 5W-30, 10W-30, 10W-40 (depending on climate). Check manual for exact recommendations.

Coolant Specification:

Mitsubishi Long Life Coolant (LLC) or equivalent ethylene glycol based antifreeze. Mix 50/50 with distilled water.

Power Steering Fluid:

ATF Dexron II/III or a specific Mitsubishi power steering fluid. Check manual for precise type.

Known Issues

Engine Mounts:

Wear and tear on engine mounts, leading to increased vibration, especially at idle.

Ignition Coils:

Failure of ignition coils, resulting in misfires and rough running.

Automatic Transmission:

Potential for delayed shifts or slipping, often related to fluid degradation or solenoid issues. Regular fluid changes are critical.

Suspension Bushings:

Degradation of rubber bushings in suspension components, leading to knocking noises and poor handling.

Exhaust System:

Corrosion and leaks in the exhaust system, particularly in areas with harsh weather.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation (MMC), Japan.

Model Evolution

Predecessor:

Mitsubishi Space Wagon (Wagon/Star Wagon).

Successor:

Mitsubishi Grandis (in some markets, though conceptually different).

Production

Production Period:

1999 - 2003 (for this specific generation covered by the manual).

Manufacturing Plant:

Likely produced in Japan.

🏆 Awards & Recognition

Recognitions

Specific Awards:

While the Space Star itself did not garner major individual awards, it was part of Mitsubishi's broader product line which aimed to provide practical and value-oriented family transport, competing in a segment that often prioritized functionality over accolades.