1999-2003 Mitsubishi Space Star Workshop Manual + Electrical Wiring Manual (Free Preview Complete FSM )

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🏷️ Basic Information Identification Make: Mitsubishi Model: Space Star Product Type: Workshop Manual + Electrical Wiring Manual Generation Model Years Covered: 1999, 2000, 2001, 2002, 2003 Codes Chassis Code: DG1W, DG4W (for specific regional variants) Engine Codes Typically Covered: 4G92, 4G93 (1.6L SOHC, 1.8L SOHC/GDI - depending on market) 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Hatchback Target Audience: Families, individuals seeking practical and versatile transportation Competitive Analysis Key Competitors: Ford Focus C-Max, Opel/Vauxhall Zafira, Renault Scénic, Volkswagen Golf SV/Touran, Fiat Multipla (in some markets) Competitive Advantage: Compact exterior dimensions with surprisingly spacious and flexible interior, known for reliability in its class. Key Features Interior Flexibility: Sliding rear seats, fold-flat rear seats, often a practical and adaptable cabin layout. Design Philosophy: Maximizing interior space within a compact footprint, practical for urban environments. Manual Value Proposition: Provides essential, factory-backed information for maintaining and repairing the vehicle, saving significant costs compared to dealership service. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive mechanical and electrical systems Secondary Coverage: Bodywork, chassis, diagnostics, maintenance, repair procedures Page Count Estimated Workshop Manual Pages: ~1500-2000+ pages (typical for a full FSM) Estimated Wiring Manual Pages: ~300-500+ pages (typical for a dedicated EWM) Manual Type Type: Factory Service Manual (FSM) / Workshop Manual & Electrical Wiring Manual Language Language: English Format Format: Digital (PDF) - indicated by 'Free Preview Complete FSM' 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including GDI if applicable), fuel system, ignition system, lubrication, cooling, exhaust, engine management (ECU diagnostics and component testing) Transmission: Manual transmission (clutch, gearbox), Automatic transmission (ATF specifications, hydraulic control, electronic control, torque converter, teardown and assembly) Drivetrain: Front-wheel drive (FWD) axles, differentials, drive shafts Chassis And Suspension: Front suspension (MacPherson strut), Rear suspension (multi-link/torsion beam depending on variant), steering system (power steering), wheel alignment specifications, hub bearings Brakes: Front disc brakes, rear drum or disc brakes, ABS system (operation, diagnostics, bleeding procedures), parking brake Electrical System Main: 12V battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), horn, wipers and washers Electrical System Comfort Convenience: Power windows, power door locks, central locking, mirrors, climate control (HVAC), audio system, remote keyless entry (if equipped) Electrical System Safety Security: Airbags (SRS system - diagnostic codes, component replacement, precautions), seatbelt pre-tensioners, alarm system (if equipped) Body And Interior: Exterior panels, doors, hood, tailgate, interior trim, seats, dashboard, bumpers, glass replacement Diagnostics And Troubleshooting: OBD-II diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, component testing procedures (resistance, voltage, current measurements) Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid level checks and top-ups, brake pad/shoe replacement, belt inspection and replacement Component Replacement: Detailed step-by-step guides for replacing major components like alternator, starter, water pump, fuel pump, radiator, suspension arms, brake calipers, sensors, actuators Rebuilding Procedures: Engine overhaul (piston rings, bearings, cylinder head gasket), transmission overhaul (seals, clutches, bands), brake caliper rebuilding Wiring Diagrams: Complete circuit diagrams for all electrical systems, component location diagrams, connector pinouts, wire colors Special Tools: Identification and usage of special tools required for specific repair procedures Technical Depth Depth: Full factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts Diagnostic Capability: Includes sensor data interpretation, ECU relearn procedures, and fault code analysis 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - High resolution, searchable text Print Quality Resolution: High-resolution scans of original factory manuals, ensuring clarity of text and diagrams Diagram Clarity: Crisp, clear technical illustrations, schematics, and wiring diagrams Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type 1: Inline-4 Cylinder, SOHC (Single Overhead Camshaft) Engine Displacement 1: 1.6 Liters (1597 cc) Engine Code Example 1: 4G92 Engine Bore Stroke 1: 81.0 mm x 77.5 mm (approximate for 4G92) Engine Compression Ratio 1: 9.5:1 to 10.0:1 (typical for 4G92) Engine Horsepower 1: 90-105 PS (66-77 kW) @ 5500-6000 rpm (approximate) Engine Torque 1: 137-150 Nm (101-111 lb-ft) @ 3000-4000 rpm (approximate) Engine Variants Engine Type 2: Inline-4 Cylinder, DOHC (Double Overhead Camshaft) or GDI (Gasoline Direct Injection) Engine Displacement 2: 1.8 Liters (1834 cc) Engine Code Example 2: 4G93 Engine Bore Stroke 2: 81.0 mm x 89.3 mm (approximate for 4G93) Engine Compression Ratio 2: 9.8:1 to 10.5:1 (typical for 4G93 SOHC/GDI) Engine Horsepower 2: 115-125 PS (85-92 kW) @ 5500-6000 rpm (approximate for SOHC), 120-140 PS for GDI variants Engine Torque 2: 165-180 Nm (122-133 lb-ft) @ 3500-4500 rpm (approximate for SOHC), 180-200 Nm for GDI variants Performance Fuel Type: Unleaded Gasoline (RON 91 or higher recommended) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) for certain variants. Fuel Pump Type: In-tank electric fuel pump Fuel Pressure: Typically 3-4 bar (43-58 psi) for MPI systems (check specific engine...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Space Star

Product Type:

Workshop Manual + Electrical Wiring Manual

Generation

Model Years Covered:

1999, 2000, 2001, 2002, 2003

Codes

Chassis Code:

DG1W, DG4W (for specific regional variants)

Engine Codes Typically Covered:

4G92, 4G93 (1.6L SOHC, 1.8L SOHC/GDI - depending on market)

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Hatchback

Target Audience:

Families, individuals seeking practical and versatile transportation

Competitive Analysis

Key Competitors:

Ford Focus C-Max, Opel/Vauxhall Zafira, Renault Scénic, Volkswagen Golf SV/Touran, Fiat Multipla (in some markets)

Competitive Advantage:

Compact exterior dimensions with surprisingly spacious and flexible interior, known for reliability in its class.

Key Features

Interior Flexibility:

Sliding rear seats, fold-flat rear seats, often a practical and adaptable cabin layout.

Design Philosophy:

Maximizing interior space within a compact footprint, practical for urban environments.

Manual Value Proposition:

Provides essential, factory-backed information for maintaining and repairing the vehicle, saving significant costs compared to dealership service.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive mechanical and electrical systems

Secondary Coverage:

Bodywork, chassis, diagnostics, maintenance, repair procedures

Page Count

Estimated Workshop Manual Pages:

~1500-2000+ pages (typical for a full FSM)

Estimated Wiring Manual Pages:

~300-500+ pages (typical for a dedicated EWM)

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual & Electrical Wiring Manual

Language

Language:

English

Format

Format:

Digital (PDF) - indicated by 'Free Preview Complete FSM'

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (including GDI if applicable), fuel system, ignition system, lubrication, cooling, exhaust, engine management (ECU diagnostics and component testing)

Transmission:

Manual transmission (clutch, gearbox), Automatic transmission (ATF specifications, hydraulic control, electronic control, torque converter, teardown and assembly)

Drivetrain:

Front-wheel drive (FWD) axles, differentials, drive shafts

Chassis And Suspension:

Front suspension (MacPherson strut), Rear suspension (multi-link/torsion beam depending on variant), steering system (power steering), wheel alignment specifications, hub bearings

Brakes:

Front disc brakes, rear drum or disc brakes, ABS system (operation, diagnostics, bleeding procedures), parking brake

Electrical System Main:

12V battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), horn, wipers and washers

Electrical System Comfort Convenience:

Power windows, power door locks, central locking, mirrors, climate control (HVAC), audio system, remote keyless entry (if equipped)

Electrical System Safety Security:

Airbags (SRS system - diagnostic codes, component replacement, precautions), seatbelt pre-tensioners, alarm system (if equipped)

Body And Interior:

Exterior panels, doors, hood, tailgate, interior trim, seats, dashboard, bumpers, glass replacement

Diagnostics And Troubleshooting:

OBD-II diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, component testing procedures (resistance, voltage, current measurements)

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), spark plug replacement, fluid level checks and top-ups, brake pad/shoe replacement, belt inspection and replacement

Component Replacement:

Detailed step-by-step guides for replacing major components like alternator, starter, water pump, fuel pump, radiator, suspension arms, brake calipers, sensors, actuators

Rebuilding Procedures:

Engine overhaul (piston rings, bearings, cylinder head gasket), transmission overhaul (seals, clutches, bands), brake caliper rebuilding

Wiring Diagrams:

Complete circuit diagrams for all electrical systems, component location diagrams, connector pinouts, wire colors

Special Tools:

Identification and usage of special tools required for specific repair procedures

Technical Depth

Depth:

Full factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts

Diagnostic Capability:

Includes sensor data interpretation, ECU relearn procedures, and fault code analysis

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - High resolution, searchable text

Print Quality

Resolution:

High-resolution scans of original factory manuals, ensuring clarity of text and diagrams

Diagram Clarity:

Crisp, clear technical illustrations, schematics, and wiring diagrams

Binding Type

Physical Binding:

N/A (Digital Format)

Paper Type

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type 1:

Inline-4 Cylinder, SOHC (Single Overhead Camshaft)

Engine Displacement 1:

1.6 Liters (1597 cc)

Engine Code Example 1:

Engine Bore Stroke 1:

81.0 mm x 77.5 mm (approximate for 4G92)

Engine Compression Ratio 1:

9.5:1 to 10.0:1 (typical for 4G92)

Engine Horsepower 1:

90-105 PS (66-77 kW) @ 5500-6000 rpm (approximate)

Engine Torque 1:

137-150 Nm (101-111 lb-ft) @ 3000-4000 rpm (approximate)

Engine Variants

Engine Type 2:

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

Engine Displacement 2:

1.8 Liters (1834 cc)

Engine Code Example 2:

Engine Bore Stroke 2:

81.0 mm x 89.3 mm (approximate for 4G93)

Engine Compression Ratio 2:

9.8:1 to 10.5:1 (typical for 4G93 SOHC/GDI)

Engine Horsepower 2:

115-125 PS (85-92 kW) @ 5500-6000 rpm (approximate for SOHC), 120-140 PS for GDI variants

Engine Torque 2:

165-180 Nm (122-133 lb-ft) @ 3500-4500 rpm (approximate for SOHC), 180-200 Nm for GDI variants

Performance

Fuel Type:

Unleaded Gasoline (RON 91 or higher recommended)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) for certain variants.

Fuel Pump Type:

In-tank electric fuel pump

Fuel Pressure:

Typically 3-4 bar (43-58 psi) for MPI systems (check specific engine variant)

🔧 Transmission

Standard

Type 1:

5-speed Manual Transmission

Optional

Type 2:

4-speed Automatic Transmission (INVECS-II technology common)

Features

Manual Gear Ratios:

Specific ratios vary by engine and transmission model, detailed in the manual.

Automatic Features:

Sport mode, Winter mode (on some variants)

Fluid Specification

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 75W-85 synthetic gear oil (verify specific recommendation)

Automatic Transmission Fluid:

Mitsubishi Dia Queen SP-III (or equivalent ATF meeting the specification) - typically 7-8 liters capacity.

📐 Dimensions

Exterior

Length:

Approx. 4185 mm (164.8 in)

Width:

Approx. 1690 mm (66.5 in)

Height:

Approx. 1550 mm (61.0 in)

Wheelbase:

Approx. 2650 mm (104.3 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Interior

Passenger Capacity:

5 Seats

Cargo

Cargo Volume Seats Up:

Approx. 370-420 Liters (Varies with seat positioning)

Cargo Volume Seats Down:

Approx. 1570-1700 Liters (Varies with seat configuration)

Weights

Curb Weight:

Approx. 1200-1350 kg (2645-2976 lbs) depending on engine and equipment

Gross Vehicle Weight Rating Gvwr:

Approx. 1700-1800 kg (3748-3968 lbs) (check specific model)

Towing Capacity:

Typically not recommended or very limited for this class of vehicle without specific factory provisions.

Wheels And Tires

Standard Wheel Size:

14-inch or 15-inch steel or alloy wheels

Standard Tire Size:

175/70R14 or 185/65R15 (verify specific trim/option)

Bolt Pattern:

4x114.3 mm (4x4.5 inches)

Center Bore:

67.1 mm

🛡️ Safety Features

Ratings

Crash Test Results:

Refer to Euro NCAP or NHTSA for specific model year test results. Generally performed well for its class at the time of release.

Active Features

Anti-Lock Braking System ABS:

Optional on most models, standard on higher trims or later years.

Electronic Brakeforce Distribution Ebd:

Often integrated with ABS systems.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional or standard on higher trims.

Seatbelts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts.

Child Seat Anchors:

ISOFIX/LATCH anchors (availability may vary by market).

Child Safety Locks:

Standard on rear doors.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette player or CD player. Speaker configuration typically 4-6 speakers. Auxiliary input was rare for this era.

Display Technology:

Basic LCD displays for radio and climate control. No large touchscreens or navigation systems available from the factory.

Driver Assistance

Cruise Control:

Optional on higher trim levels.

Parking Assistance:

No factory-provided parking sensors or rearview cameras. Parking was purely manual.

Connectivity

Bluetooth:

Not available from factory.

Usb Ports:

Not available from factory.

Other Features

Remote Keyless Entry:

Available as an option on certain trim levels.

Immobilizer:

Standard in many markets to prevent theft.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first. (Refer to manual for specific interval based on driving conditions).

Air Filter Replacement:

Every 30,000-45,000 km (18,000-28,000 miles) or 24 months.

Cabin Air Filter:

Every 15,000-20,000 km (9,000-12,000 miles) or 12 months, crucial for cabin air quality.

Spark Plugs:

Platinum-tipped plugs: 90,000-120,000 km (56,000-75,000 miles). Standard plugs: 40,000-60,000 km (25,000-37,000 miles). (Verify plug type in manual).

Timing Belt Replacement:

For 4G92/4G93 engines: Typically 90,000-100,000 km (56,000-62,000 miles) or 5 years. Critical to replace as failure can cause catastrophic engine damage.

Brake Fluid Flush:

Every 2-3 years or 40,000-60,000 km (25,000-37,000 miles).

Coolant Flush:

Every 40,000-60,000 km (25,000-37,000 miles) or 2-3 years.

Fluid Specifications

Engine Oil Viscosity:

Typically 10W-40 or 5W-40 synthetic (depending on climate). Check manual for exact recommendation.

Engine Oil Capacity:

Approx. 4.0-4.5 liters (4.2-4.8 US quarts) with filter change for 1.6L/1.8L engines.

Coolant Type:

Ethylene glycol-based antifreeze, typically a pink or red long-life formula (Mitsubishi Super Long Life Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Wear Items:

Front suspension components (bushings, ball joints, tie rod ends), wheel bearings, exhaust system components, radiator.

Electrical Gremlins:

Can be susceptible to minor electrical issues over time, such as faulty door lock actuators, intermittent interior lighting, or minor sensor failures. Wiring diagrams are crucial for diagnosis.

Engine Performance Issues:

Idle speed control valve issues, injector clogging (especially on GDI variants), occasional oil leaks from valve cover gaskets or oil pan gaskets.

Transmission Issues:

Automatic transmission may exhibit delayed engagement or harsh shifting if fluid is old or ATF filter is clogged. Manual transmissions are generally robust but clutch wear is normal.

Corrosion:

Like many vehicles of this era, particularly those sold in regions with road salt, rust can affect wheel arches, sills, and underbody components.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Japanese automaker with a long history in automotive manufacturing, known for durable and innovative vehicles, particularly in the SUV and performance sectors (Lancer Evolution).

Model Evolution

First Generation:

The Mitsubishi Space Star (also known as Mitsubishi Carisma in some markets for certain platforms, though Space Star is distinct) was introduced in the late 1990s as Mitsubishi's entry into the compact MPV segment.

Platform Sharing:

Based on Mitsubishi's Global Performance Platform (GPP), shared elements with the Mitsubishi Lancer models of the era.

Design Intent:

Designed to offer a practical, family-oriented vehicle with flexible seating and a spacious interior, contrasting with more conventional hatchback designs.

Production

Production Period:

1998-2005 (First Generation)

Manufacturing Locations:

Primarily produced in Europe (e.g., Netherlands by NedCar) and Japan.

Market Availability:

Widely sold in Europe, Australia, and other international markets. Less common in North America.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Specific safety awards would need to be verified by model year and region, but generally aimed for good ratings within its class.

Ratings

Reliability Ratings:

Generally considered average to good for its class and era. Maintenance as per schedule is key to long-term reliability.

Certifications

Emissions Standards:

Compliant with Euro 3/4 or equivalent emissions standards for the applicable model years.