1999-2003 Mitsubishi Space Star Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Space Star Model Years Covered: 1999, 2000, 2001, 2002, 2003 Codes Chassis Codes: DE3A (Global variant), DG1A (North American variant - essentially a rebadged Mitsubishi Carisma) Engine Codes Primary: 4G93 (1.8L SOHC MPI), 4G94 (2.0L DOHC GDI - prevalent in some markets) Engine Codes Secondary: 4G13 (1.3L SOHC MPI - less common in North America), 4G15 (1.5L SOHC MPI) 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Minivan Target Audience: Families seeking a practical, versatile, and fuel-efficient vehicle. Competitive Analysis Key Competitors: Ford Focus Wagon, Volkswagen Golf Variant, Opel/Vauxhall Astra Caravan, Renault Scenic, Citroen Picasso, Toyota Corolla Verso Key Features Unique Selling Points: Spacious and flexible interior for its size, good fuel economy (especially with smaller engines), practical sliding rear doors (in some configurations/markets), reputation for reliability (generally). Manual Value Proposition: Provides owners and independent mechanics with the essential technical knowledge to maintain, diagnose, and repair the Space Star, saving on dealership service costs and extending vehicle lifespan. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Body, Chassis, Maintenance, Diagnostics, Troubleshooting, Repair Procedures Specific Systems Covered: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Drive Axles, Suspension, Steering, Brakes, ABS, HVAC, Body Electrical, Lighting, Body Hardware, Body Panels, Interior Trim, SRS (Airbag) System, On-Board Diagnostics (OBD-II) Page Count Estimated Page Count: 1500-2000+ pages (typical for a comprehensive workshop manual) Manual Type Manual Type: Workshop Manual / Service Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly/disassembly, cylinder head, valve train, pistons, connecting rods, crankshaft, timing belt/chain, lubrication system (oil pump, oil filter), cooling system (radiator, water pump, thermostat), fuel delivery system (injectors, fuel pump, fuel filter), ignition system, emission control systems, exhaust manifold, catalytic converter Transmission Drivetrain: Manual transmission (gearbox removal, overhaul, clutch replacement), Automatic transmission (removal, overhaul, torque converter, valve body, solenoids, fluid changes), transaxle, drive shafts, CV joints, differential Brakes Suspension Steering: Brake system (discs, pads, calipers, master cylinder, brake lines, ABS components), suspension components (struts, shocks, springs, control arms, ball joints, bushings), steering system (steering rack, power steering pump, steering column, tie rod ends), wheel alignment specifications Electrical Electronics: Wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), charging system (alternator, battery), starting system (starter motor), instrument cluster, power windows, power locks, wipers, horn, SRS (airbag) system, audio system, immobilizer system Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, belt inspection and replacement, battery checks, tire rotation and pressure checks Diagnostic Procedures: OBD-II code reading and interpretation, trouble shooting charts, component testing procedures, sensor data analysis, fuel system pressure testing, ignition system testing Repair And Rebuild: Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement, transmission rebuild, clutch replacement, brake caliper overhaul, suspension component replacement, steering rack replacement, starter/alternator replacement, fuel injector cleaning/replacement Technical Depth Depth Of Information: Comprehensive; covers detailed component removal, installation, adjustment, overhaul, and diagnostic procedures. Includes torque specifications, clearances, and assembly sequences. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Digital Resolution: High-resolution scans suitable for clear viewing and printing of diagrams and text. Binding Type Binding Type Digital: N/A (Digital file) Paper Type Paper Type Digital: N/A (Digital file) Searchability Text Searchability: Searchable text within PDF allows for quick location of specific topics or keywords. ⚙️ Engine Specifications Primary Engine Engine Name Primary: 4G93 SOHC MPI Engine Displacement Primary: 1834 cc Engine Configuration Primary: Inline 4-cylinder, SOHC (Single Overhead Camshaft), Multi-Point Fuel Injection (MPI) Bore X Stroke Primary: 81.0 mm x 89.0 mm Compression Ratio Primary: 9.8:1 (typical) Horsepower Primary: Approx. 115-120 PS (85-89 kW) @ 5500-6000 rpm Torque Primary: Approx. 165-170 Nm (122-125 lb-ft) @ 4000-4500 rpm Secondary Engine Engine Name Secondary: 4G94 DOHC GDI Engine Displacement Secondary: 1997 cc Engine Configuration Secondary: Inline 4-cylinder, DOHC (Double Overhead Camshaft), Gasoline Direct Injection (GDI) Horsepower Secondary: Approx. 130-135 PS (96-100 kW) @ 6000 rpm Torque Secondary: Approx. 180-185 Nm (133-137 lb-ft) @ 4000 rpm Fuel System Fuel Type: Unleaded gasoline Fuel Delivery System: Multi-Point Fuel Injection (MPI) for 4G93, Gasoline Direct Injection (GDI) for 4G94 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission Optional Optional Transmission: 4-speed automatic transmission (INVECS-II with AI shift control) Features Automatic Transmission Features: Sport mode, Winter mode (in some variants) Fluid Specifications Manual Transmission Fluid Type: API GL-4, SAE 75W-90 or SAE 75W-85 Automatic Transmission Fluid Type: DIA QUEEN ATF-SP (or equivalent DEXRON II/III compatible fluid) Fluid Capacities Manual Transmission Fluid Capacity: Approx. 2.2 Liters (2.3 US Quarts) Automatic Transmission Fluid Capacity: Approx. 6.0 Liters (6.3 US Quarts) (Total fill, including torque converter) 📐 Dimensions Exterior Length: Approx. 4185 mm (164.8 in) Width: Approx. 1695 mm (66.7 in) Height: Approx. 1545 mm (60.8...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Space Star

Model Years Covered:

1999, 2000, 2001, 2002, 2003

Codes

Chassis Codes:

DE3A (Global variant), DG1A (North American variant - essentially a rebadged Mitsubishi Carisma)

Engine Codes Primary:

4G93 (1.8L SOHC MPI), 4G94 (2.0L DOHC GDI - prevalent in some markets)

Engine Codes Secondary:

4G13 (1.3L SOHC MPI - less common in North America), 4G15 (1.5L SOHC MPI)

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Minivan

Target Audience:

Families seeking a practical, versatile, and fuel-efficient vehicle.

Competitive Analysis

Key Competitors:

Ford Focus Wagon, Volkswagen Golf Variant, Opel/Vauxhall Astra Caravan, Renault Scenic, Citroen Picasso, Toyota Corolla Verso

Key Features

Unique Selling Points:

Spacious and flexible interior for its size, good fuel economy (especially with smaller engines), practical sliding rear doors (in some configurations/markets), reputation for reliability (generally).

Manual Value Proposition:

Provides owners and independent mechanics with the essential technical knowledge to maintain, diagnose, and repair the Space Star, saving on dealership service costs and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Body, Chassis, Maintenance, Diagnostics, Troubleshooting, Repair Procedures

Specific Systems Covered:

Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Manual Transmission, Automatic Transmission, Drive Axles, Suspension, Steering, Brakes, ABS, HVAC, Body Electrical, Lighting, Body Hardware, Body Panels, Interior Trim, SRS (Airbag) System, On-Board Diagnostics (OBD-II)

Page Count

Estimated Page Count:

1500-2000+ pages (typical for a comprehensive workshop manual)

Manual Type

Manual Type:

Workshop Manual / Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly/disassembly, cylinder head, valve train, pistons, connecting rods, crankshaft, timing belt/chain, lubrication system (oil pump, oil filter), cooling system (radiator, water pump, thermostat), fuel delivery system (injectors, fuel pump, fuel filter), ignition system, emission control systems, exhaust manifold, catalytic converter

Transmission Drivetrain:

Manual transmission (gearbox removal, overhaul, clutch replacement), Automatic transmission (removal, overhaul, torque converter, valve body, solenoids, fluid changes), transaxle, drive shafts, CV joints, differential

Brakes Suspension Steering:

Brake system (discs, pads, calipers, master cylinder, brake lines, ABS components), suspension components (struts, shocks, springs, control arms, ball joints, bushings), steering system (steering rack, power steering pump, steering column, tie rod ends), wheel alignment specifications

Electrical Electronics:

Wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior), charging system (alternator, battery), starting system (starter motor), instrument cluster, power windows, power locks, wipers, horn, SRS (airbag) system, audio system, immobilizer system

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, belt inspection and replacement, battery checks, tire rotation and pressure checks

Diagnostic Procedures:

OBD-II code reading and interpretation, trouble shooting charts, component testing procedures, sensor data analysis, fuel system pressure testing, ignition system testing

Repair And Rebuild:

Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement, transmission rebuild, clutch replacement, brake caliper overhaul, suspension component replacement, steering rack replacement, starter/alternator replacement, fuel injector cleaning/replacement

Technical Depth

Depth Of Information:

Comprehensive; covers detailed component removal, installation, adjustment, overhaul, and diagnostic procedures. Includes torque specifications, clearances, and assembly sequences.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Digital Resolution:

High-resolution scans suitable for clear viewing and printing of diagrams and text.

Binding Type

Binding Type Digital:

N/A (Digital file)

Paper Type

Paper Type Digital:

N/A (Digital file)

Searchability

Text Searchability:

Searchable text within PDF allows for quick location of specific topics or keywords.

⚙️ Engine Specifications

Primary Engine

Engine Name Primary:

4G93 SOHC MPI

Engine Displacement Primary:

1834 cc

Engine Configuration Primary:

Inline 4-cylinder, SOHC (Single Overhead Camshaft), Multi-Point Fuel Injection (MPI)

Bore X Stroke Primary:

81.0 mm x 89.0 mm

Compression Ratio Primary:

9.8:1 (typical)

Horsepower Primary:

Approx. 115-120 PS (85-89 kW) @ 5500-6000 rpm

Torque Primary:

Approx. 165-170 Nm (122-125 lb-ft) @ 4000-4500 rpm

Secondary Engine

Engine Name Secondary:

4G94 DOHC GDI

Engine Displacement Secondary:

1997 cc

Engine Configuration Secondary:

Inline 4-cylinder, DOHC (Double Overhead Camshaft), Gasoline Direct Injection (GDI)

Horsepower Secondary:

Approx. 130-135 PS (96-100 kW) @ 6000 rpm

Torque Secondary:

Approx. 180-185 Nm (133-137 lb-ft) @ 4000 rpm

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Delivery System:

Multi-Point Fuel Injection (MPI) for 4G93, Gasoline Direct Injection (GDI) for 4G94

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission

Optional

Optional Transmission:

4-speed automatic transmission (INVECS-II with AI shift control)

Features

Automatic Transmission Features:

Sport mode, Winter mode (in some variants)

Fluid Specifications

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 or SAE 75W-85

Automatic Transmission Fluid Type:

DIA QUEEN ATF-SP (or equivalent DEXRON II/III compatible fluid)

Fluid Capacities

Manual Transmission Fluid Capacity:

Approx. 2.2 Liters (2.3 US Quarts)

Automatic Transmission Fluid Capacity:

Approx. 6.0 Liters (6.3 US Quarts) (Total fill, including torque converter)

📐 Dimensions

Exterior

Length:

Approx. 4185 mm (164.8 in)

Width:

Approx. 1695 mm (66.7 in)

Height:

Approx. 1545 mm (60.8 in)

Wheelbase:

Approx. 2650 mm (104.3 in)

Front Track:

Approx. 1470 mm (57.9 in)

Rear Track:

Approx. 1470 mm (57.9 in)

Weights

Curb Weight:

Approx. 1250-1350 kg (2755-2976 lbs), depending on engine and transmission

Gross Vehicle Weight Rating Gvwr:

Typically around 1700-1800 kg (3750-3970 lbs)

Cargo

Cargo Volume Rear Seats Up:

Approx. 420 Liters (14.8 cu ft)

Cargo Volume Rear Seats Folded:

Approx. 1570 Liters (55.4 cu ft)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

Not consistently rated or data may vary by market and specific year. Generally considered average for its class at the time.

Euro Ncap Rating:

3-star (for models tested in European markets, e.g., 1999-2003 model tested by Euro NCAP)

Active Features

ABS Availability:

Optional on most trims, standard on higher trims and later models.

Traction Control Availability:

Rarely available, typically not a standard or common option for this generation.

Passive Features

Airbags Front:

Driver and passenger front airbags standard on most models.

Airbags Side:

Optional side airbags available on some higher trims or later models.

Seatbelts:

Three-point seatbelts with pretensioners for front seats, three-point or lap belts for rear seats.

Child Seat Anchors:

ISOFIX/LATCH anchor points available on rear seats (availability varies by market/trim).

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM radio with CD player or cassette tape player. Optional premium audio systems with more speakers.

Navigation System:

Not commonly available for this model year. Aftermarket options were more prevalent.

Driver Assistance

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Rarely available, not a common factory feature.

Connectivity

Bluetooth:

Not available from factory. Aftermarket head unit installation is required.

Usb Port:

Not available from factory.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Consult manual for specific engine type and oil used.

Engine Oil Filter Change:

Replace at every engine oil change.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Spark Plug Replacement:

Platinum/Iridium plugs: Every 60,000 miles (96,000 km). Copper plugs: Every 30,000 miles (48,000 km).

Timing Belt Replacement:

Crucial item. Every 60,000 miles (96,000 km) or 4 years. Failure can cause severe engine damage.

Coolant Replacement:

Every 30,000 miles (48,000 km) or 2 years.

Brake Fluid Replacement:

Every 24 months or 30,000 miles (48,000 km).

Fluid Specifications

Engine Oil Specification:

API SG or higher, SAE 10W-30 or SAE 5W-30 (check owner's manual for climate suitability).

Coolant Specification:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with demineralized water (50/50 mix).

Brake Fluid Specification:

DOT 3 or DOT 4.

Known Issues

Common Problems Engine:

Timing belt failure (if not replaced on schedule), occasional issues with engine sensors (e.g., crankshaft position sensor), potential carbon buildup with GDI engines.

Common Problems Transmission:

Clutch wear (manual transmission), occasional automatic transmission solenoid or valve body issues, minor leaks.

Common Problems Suspension Steering:

Worn control arm bushings, worn ball joints, power steering fluid leaks, worn steering rack seals.

Common Problems Electrical:

Corrosion on electrical connectors, aging wiring harnesses, occasional issues with power window motors, instrument cluster faults.

Common Problems Body:

Rust on body panels (especially wheel arches and sills), interior trim creaks and rattles, aging weatherstripping.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Legacy:

Mitsubishi Motors has a long history in automotive manufacturing, known for its robust engineering and participation in motorsports (e.g., Rally). The Space Star represents their entry into the compact MPV segment.

Model Evolution

Generation Introduction:

The first generation Space Star (also known as the Space Wagon or Nimbus in some markets) was introduced in 1998/1999, replacing the older Mitsubishi Space Runner. The North American version, sold as the Mitsubishi M space, was essentially a rebadged Mitsubishi Carisma hatchback.

Facelifts And Updates:

A minor facelift occurred around 2001-2002, with updated styling (grille, headlights, bumpers) and some interior trim enhancements. Engine options were refined in certain markets.

Production

Manufacturing Locations:

Primarily manufactured in Japan (Mizushima Plant) and the Netherlands (NedCar plant) for European markets. North American versions (as a rebadged Carisma) may have had different origins.

Production Years:

1998-2004 (First Generation)

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the Space Star are not widely publicized, it was generally well-received in Europe for its practicality and value, contributing to Mitsubishi's market presence in the compact MPV segment.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and specific components, with some years showing average to above-average reliability, while others experienced more common issues in specific areas.