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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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1999-2003 Mitsubishi Space Star Workshop Service Repair Manual 1999 2000 2001 2002 2003
🏷️ 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 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
ABS:
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.
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