1999-2003 Mitsubishi Space Star Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Space Star Model Generation: First Generation (DG1A/DG4A) Model Code: DG1A (FWD), DG4A (4WD) Codes Engine Codes Covered: 4G93, 4G94 Chassis Codes Covered: DG1A, DG4A 👋 Introduction Market Position Segment: Compact MPV (Multi-Purpose Vehicle) / Mini MPV Target Audience: Families seeking a practical, fuel-efficient, and versatile vehicle for urban and suburban use. Competitive Analysis Key Competitors: Honda Stream, Toyota Ipsum/Picnic, Ford Focus C-Max, Renault Scenic, Opel/Vauxhall Zafira. Key Features Design Philosophy: Compact exterior dimensions with a surprisingly spacious and flexible interior, emphasizing practicality and modularity. Practicality: Sliding rear doors (in some markets), fold-flat seating configurations, elevated driving position for good visibility. 📋 Manual Details Coverage Areas Coverage Years: 1999, 2000, 2001, 2002, 2003 Regions Covered: North America, Europe (Specific markets may vary by engine/trim) Page Count Total Pages: Approximately 2000+ pages (comprehensive digital format) Manual Type Type: Factory Service Manual / Repair Manual Completeness: Full factory service manual coverage for all systems. Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, overhaul, timing belt, cylinder head, pistons, crankshaft, oil pump, cooling system, lubrication system. Engine Management: Fuel injection system (MPI), ignition system, emission control system, ECU diagnosis, sensors (O2, MAP, TPS, CKP, CMP), actuators. Transmission Manual: Clutch, gearbox overhaul, gear selection, differential, maintenance, repair procedures. Transmission Automatic: ATF type and capacity, torque converter, valve body, internal components, diagnostic procedures, solenoid operation, overhaul. Drivetrain: Front wheel drive axles, CV joints, rear axle (4WD), driveshafts, transfer case (4WD), propeller shaft. Suspension: Front suspension (MacPherson struts, control arms), rear suspension (multi-link), shock absorbers, springs, bushings, wheel alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, steering angle sensor (if equipped). Brakes: Front disc brakes, rear drum brakes (common) or disc brakes (optional), ABS system (if...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Space Star

Model Generation:

First Generation (DG1A/DG4A)

Model Code:

DG1A (FWD), DG4A (4WD)

Codes

Engine Codes Covered:

4G93, 4G94

Chassis Codes Covered:

DG1A, DG4A

👋 Introduction

Market Position

Segment:

Compact MPV (Multi-Purpose Vehicle) / Mini MPV

Target Audience:

Families seeking a practical, fuel-efficient, and versatile vehicle for urban and suburban use.

Competitive Analysis

Key Competitors:

Honda Stream, Toyota Ipsum/Picnic, Ford Focus C-Max, Renault Scenic, Opel/Vauxhall Zafira.

Key Features

Design Philosophy:

Compact exterior dimensions with a surprisingly spacious and flexible interior, emphasizing practicality and modularity.

Practicality:

Sliding rear doors (in some markets), fold-flat seating configurations, elevated driving position for good visibility.

📋 Manual Details

Coverage Areas

Coverage Years:

1999, 2000, 2001, 2002, 2003

Regions Covered:

North America, Europe (Specific markets may vary by engine/trim)

Page Count

Total Pages:

Approximately 2000+ pages (comprehensive digital format)

Manual Type

Type:

Factory Service Manual / Repair Manual

Completeness:

Full factory service manual coverage for all systems.

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul, timing belt, cylinder head, pistons, crankshaft, oil pump, cooling system, lubrication system.

Engine Management:

Fuel injection system (MPI), ignition system, emission control system, ECU diagnosis, sensors (O2, MAP, TPS, CKP, CMP), actuators.

Transmission Manual:

Clutch, gearbox overhaul, gear selection, differential, maintenance, repair procedures.

Transmission Automatic:

ATF type and capacity, torque converter, valve body, internal components, diagnostic procedures, solenoid operation, overhaul.

Drivetrain:

Front wheel drive axles, CV joints, rear axle (4WD), driveshafts, transfer case (4WD), propeller shaft.

Suspension:

Front suspension (MacPherson struts, control arms), rear suspension (multi-link), shock absorbers, springs, bushings, wheel alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, steering angle sensor (if equipped).

Brakes:

Front disc brakes, rear drum brakes (common) or disc brakes (optional), ABS system (if equipped), brake fluid type, bleeding procedures, parking brake.

Electrical System:

Battery, charging system (alternator, starter), lighting system, ignition switch, fuses, relays, wiring diagrams, multiplex communication system.

Body Exterior:

Body panel removal/installation, doors, hood, tailgate, bumpers, glass replacement, seals, trim.

Body Interior:

Dashboard, seats, door panels, headliner, HVAC controls, trim pieces, airbag system components.

Climate Control:

HVAC system operation, refrigerant, compressor, condenser, evaporator, heater core, blower motor, diagnosis and repair.

Safety Systems:

Airbag system (SRS) components, seat belt pre-tensioners, diagnostics, replacement procedures.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, fluid checks, tire rotation, spark plug replacement, belt inspection.

Diagnostics Troubleshooting:

Step-by-step diagnostic procedures for common symptoms, fault code interpretation (OBD-II), circuit testing.

Engine Repair:

Complete engine overhaul, head gasket replacement, timing belt replacement, component testing.

Transmission Repair:

Automatic transmission fluid flush and fill, solenoid replacement, manual gearbox clutch replacement, transmission overhaul.

Brake Service:

Brake pad and rotor replacement, brake caliper service, brake fluid flush, ABS component testing.

Electrical Repairs:

Wiring harness repair, component replacement (alternator, starter, sensors), diagnostic tool usage.

Bodywork Repair:

Door hinge adjustment, panel alignment, bumper replacement, glass seal replacement.

Suspension Steering Repair:

Strut and shock replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, wheel alignment procedures.

Technical Depth

Depth:

Comprehensive: From routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

1.8 Liters (1834 cc)

Engine 1 Code:

Engine 1 Type:

Inline 4-cylinder, SOHC or DOHC (depending on market/trim)

Engine 1 Horsepower:

Approx. 118-125 HP (depending on configuration)

Engine 1 Torque:

Approx. 115-120 lb-ft (depending on configuration)

Optional Engine

Engine 2 Displacement:

2.0 Liters (1997 cc)

Engine 2 Code:

Engine 2 Type:

Inline 4-cylinder, DOHC, MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some variants

Engine 2 Horsepower:

Approx. 135-145 HP (depending on configuration)

Engine 2 Torque:

Approx. 130-135 lb-ft (depending on configuration)

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Cooling System

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent ethylene glycol based)

🔧 Transmission

Standard

Transmission Type Standard:

4-Speed Automatic Transmission (INVECS-II)

Optional

Transmission Type Optional:

5-Speed Manual Transmission

Features

At Features:

Adaptive Shift Control (INVECS-II) optimizing shift points based on driving style.

Drive Layout:

Front-Wheel Drive (FWD) standard, All-Wheel Drive (4WD) optional on select models.

Fluid Specifications

Automatic Transmission Fluid:

DiaQueen ATF-SP II M (or equivalent Dexron II/III compatible fluid)

Manual Transmission Fluid:

GL-4 gear oil, SAE 75W-90

📐 Dimensions

Exterior

Length:

Approx. 4300 mm (169.3 in)

Width:

Approx. 1700 mm (66.9 in)

Height:

Approx. 1630 mm (64.2 in)

Wheelbase:

Approx. 2650 mm (104.3 in)

Interior

Seating Capacity:

5-7 passengers (depending on configuration and market)

Cargo

Cargo Volume:

Variable, with rear seats folded approx. 480 - 1500 liters (VDA)

Weights

Curb Weight:

Approx. 1300 - 1450 kg (2866 - 3197 lbs)

Gross Vehicle Weight Rating:

Typically around 1900-2000 kg

Towing Capacity:

Varies by market, often around 500-1200 kg (unbraked/braked)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

Not extensively documented for this model's specific generation in US market. Similar era Mitsubishi models generally performed moderately.

Euro Ncap Rating:

Generally 3-4 stars for similar European models of the era.

Active Features

Anti-lock Braking System (ABS) optional or standard on higher trims.

Traction Control:

Traction Control System (TCS) available on some 4WD or higher-spec models.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional on some trims.

Seat Belts:

3-point front and rear seat belts, pre-tensioners for front belts.

Child Seat Anchors:

ISOFIX/LATCH compatible rear seats (market dependent).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player or CD player with 4-6 speakers. Aftermarket head unit upgrades are common.

Navigation:

Optional factory navigation system available on higher trims in select markets (typically CRT-based).

Driver Assistance

Cruise Control:

Available as an option on many models.

Parking Sensors:

Rarely fitted as standard, likely an aftermarket addition.

Connectivity

Usb Aux:

Not available on factory systems. Requires aftermarket adapter or head unit.

Bluetooth:

Not available on factory systems. Requires aftermarket adapter or head unit.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 7,500 miles (12,000 km) or 12 months, whichever comes first.

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter:

Replace every 15,000 - 20,000 miles (24,000 - 32,000 km) or annually.

Spark Plugs:

Platinum type: Inspect at 60,000 miles (96,000 km), replace at 100,000 miles (160,000 km). Iridium type: Up to 120,000 miles (192,000 km).

Timing Belt:

Replace every 60,000 - 90,000 miles (96,000 - 144,000 km) or 6-7 years, depending on engine type and driving conditions. Crucial due to interference engine design.

Brake Fluid:

Flush and replace every 2 years or 30,000 miles (48,000 km).

Coolant:

Replace at 30,000 miles (48,000 km) or 2 years for conventional, or follow manufacturer's long-life coolant schedule.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 5W-30 or 5W-40 recommended (check owner's manual for specific viscosity based on climate).

Power Steering Fluid:

ATF Dexron II/III or specific Mitsubishi power steering fluid.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Timing Belt Wear:

Premature failure of the timing belt or tensioner can cause catastrophic engine damage. Strict adherence to replacement intervals is vital.

Automatic Transmission Sluggishness:

Can sometimes be attributed to worn solenoids or low fluid levels/condition. Regular fluid changes are important.

Cv Joint Wear:

Front CV joints can wear over time, leading to clicking noises during turns. Inspect gaiters for tears.

Rear Suspension Noise:

Worn bushings or worn shock absorbers can lead to rattling or knocking noises from the rear.

HVAC Blower Motor:

The blower motor resistor or the motor itself can fail, leading to loss of fan speed control or complete fan failure.

Engine Oil Leaks:

Valve cover gasket or oil pan gasket can degrade and leak over time.

📚 Vehicle History

Brand Heritage

Parent Company:

Mitsubishi Motors Corporation (Japan)

Model Evolution

Predecessor:

Not a direct predecessor; the Space Star concept aimed to fill a niche for a compact MPV.

Successor:

Mitsubishi Grandis (in some markets), Mitsubishi Outlander (broader SUV segment).

Production

Production Period:

1998-2005 (First Generation)

Manufacturing Plants:

Mizushima Plant, Japan; NedCar, Netherlands (for European market).

Market Introduction

Initial Release:

Late 1998 in Japan, followed by European launch in 1999.

🏆 Awards & Recognition

Recognitions

General Reputation:

Praised for its practicality, interior space, and value for money in the compact MPV segment.

Market Awards:

Received positive reviews from automotive publications in Europe for its family-friendly features and fuel efficiency.

Certifications

Emission Standards:

Compliant with prevailing emission standards for the model years (e.g., Euro 3/4 depending on market).