Mitsubishi L200 Pickup Truck (All Variants) Complete Workshop Service Repair Manual 1997 1998 1999 2000 2001 2002 2003 2004 2005

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Pickup Truck Marketing Name Variant: Triton (in many markets) Body Style: Pickup Truck Body Configuration: Single Cab, Double Cab, Club Cab (Strada) Codes Chassis Code Prefix: K74T (4x4), K64T (4x2) Internal Generation Code: Fourth Generation (K70/K60 series) Generation Generation Years: 1996-2006 (This manual covers specific facelifted models within this generation) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size pickup truck, popular in emerging markets and for commercial/utility purposes globally. Target Audience: Commercial users, fleet owners, individuals seeking a robust and versatile utility vehicle. Competitive Analysis Key Competitors: Toyota Hilux, Nissan Navara (Frontier), Ford Ranger, Isuzu D-Max, Chevrolet Colorado. Key Features Versatility: Adaptable for various tasks, from cargo hauling to off-road adventure. Durability: Known for its rugged construction and ability to withstand demanding conditions. Engine Options: Offered with reliable and fuel-efficient diesel engines, as well as capable petrol engines. 📋 Manual Details Coverage Areas Applicable Years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Variants Covered: All variants, including 4x2, 4x4, petrol, and diesel engines, and different cab configurations (Single, Club Cab, Double Cab). Page Count Estimated Page Count: 1000+ (typical for comprehensive workshop manuals covering multiple variants and years) Manual Type Manual Type: Complete Workshop Service Repair Manual Content Focus: Maintenance, Repair, Diagnostics, Overhaul, Specifications, Troubleshooting Language Language: English Format Format: Downloadable PDF (implied by description) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system, fuel injection systems (diesel and petrol), turbocharging systems. Engine Electrical: Ignition system, starting system, charging system, ECU diagnosis, sensor locations and testing, emissions control systems. Transmission Manual: Manual gearbox (e.g., KM220, KM221 series), clutch system, driveshafts, differentials. Transmission Automatic: Automatic transmission (e.g., W4A series), torque converter, transmission control module (TCM), hydraulic systems. Drivetrain: Transfer case (4WD models), propeller shafts, axles, wheel hubs, constant velocity (CV) joints. Suspension: Front suspension (independent torsion bar or double wishbone depending on variant), rear suspension (leaf springs), shock absorbers, springs, bushings, alignment specifications. Steering: Power steering system, steering gear, steering column, tie rods, power steering pump and reservoir. Brakes: Front disc brakes, rear drum or disc brakes, hydraulic system, brake lines, master cylinder, brake booster, parking brake, ABS system (if equipped). Electrical System General: Lighting system (headlights, taillights, interior), wiring diagrams for all circuits, fuse box layouts, relay functions, battery system. Body And Chassis: Frame construction, body panels, doors, windows, glass, interior trim, seats, bumpers, towing information. HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant charging, component replacement (compressor, condenser, evaporator). Fuel System: Fuel tanks, fuel pumps, fuel lines, fuel filters, fuel injectors (diesel and petrol). Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication points, belt inspections and replacement. Engine Repair: Engine overhaul, piston and ring replacement, bearing replacement, valve adjustment, cylinder head gasket replacement, timing belt/chain replacement. Transmission Repair: Clutch replacement, gearbox overhaul, automatic transmission rebuild, seal and gasket replacement. Drivetrain Repair: Transfer case servicing, CV joint replacement, axle seal replacement, differential service. Brake System Repair: Brake pad/shoe replacement, brake rotor/drum replacement, brake fluid flush, caliper/wheel cylinder overhaul, ABS system diagnostics and repair. Electrical Troubleshooting: Diagnostic procedures for all electrical circuits, component testing using multimeters and oscilloscopes, wiring harness repair. Suspension And Steering Repair: Shock absorber replacement, ball joint and tie rod end replacement, power steering pump replacement, steering gear adjustment. Body And Interior Repair: Door lock mechanism repair, window regulator replacement, interior panel removal and installation, bumper repair, rust prevention. Diagnostic Procedures: Step-by-step troubleshooting guides for common and uncommon problems, fault code interpretation (OBD-I/OBD-II depending on region/year). Torque Specifications: Detailed torque values for all fasteners across all major systems. Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic fluid changes and inspections to full engine, transmission, and drivetrain overhauls. Diagnostic Capability: Advanced: Includes wiring diagrams, component testing procedures, and troubleshooting trees for complex electronic and mechanical issues. Special Tools: Lists and descriptions of special tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy navigation of topics. Print Quality Graphics Resolution: High-resolution diagrams, illustrations, and photographs for clarity. Layout: Organized logically by system with clear headings, subheadings, and index. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Diesel Engine Family: 4D56 (SOHC, 8-valve or 16-valve common rail in later models), 4M40 (SOHC, 8-valve, direct injection turbo diesel). Petrol Engine Family: 4G63 (DOHC, 16-valve), 6G72 (SOHC, 24-valve V6). Performance 4D56 16V Di Turbo Diesel Hp: Approx. 114 hp to 133 hp (depending on configuration and market). 4D56 16V Di Turbo Diesel Torque: Approx. 200 lb-ft to 230 lb-ft. 4M40 Turbo Diesel Hp: Approx. 103 hp to 114 hp. 4M40 Turbo Diesel Torque: Approx. 177 lb-ft to 200 lb-ft. 4G63 Petrol Hp: Approx. 133...

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Typ: Pickup Truck

Anbieter:

Art.-Nr: 489180

Sammlungen: ALL Mitsubishi

Verfügbarkeit: Auf Lager

Stichworte: 1997 1998 1999 2000 2001 2002 2003 2004 2005 Cars L200 Misc Mitsubishi Pickup Truck

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

L200 Pickup Truck

Marketing Name Variant:

Triton (in many markets)

Body Style:

Pickup Truck

Body Configuration:

Single Cab, Double Cab, Club Cab (Strada)

Codes

Chassis Code Prefix:

K74T (4x4), K64T (4x2)

Internal Generation Code:

Fourth Generation (K70/K60 series)

Generation

Generation Years:

1996-2006 (This manual covers specific facelifted models within this generation)

👋 Introduction

Market Position

Vehicle Segment:

Compact/Mid-size pickup truck, popular in emerging markets and for commercial/utility purposes globally.

Target Audience:

Commercial users, fleet owners, individuals seeking a robust and versatile utility vehicle.

Competitive Analysis

Key Competitors:

Toyota Hilux, Nissan Navara (Frontier), Ford Ranger, Isuzu D-Max, Chevrolet Colorado.

Key Features

Versatility:

Adaptable for various tasks, from cargo hauling to off-road adventure.

Durability:

Known for its rugged construction and ability to withstand demanding conditions.

Engine Options:

Offered with reliable and fuel-efficient diesel engines, as well as capable petrol engines.

📋 Manual Details

Coverage Areas

Applicable Years:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

Variants Covered:

All variants, including 4x2, 4x4, petrol, and diesel engines, and different cab configurations (Single, Club Cab, Double Cab).

Page Count

Estimated Page Count:

1000+ (typical for comprehensive workshop manuals covering multiple variants and years)

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Content Focus:

Maintenance, Repair, Diagnostics, Overhaul, Specifications, Troubleshooting

Language

Language:

English

Format

Format:

Downloadable PDF (implied by description)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling system, fuel injection systems (diesel and petrol), turbocharging systems.

Engine Electrical:

Ignition system, starting system, charging system, ECU diagnosis, sensor locations and testing, emissions control systems.

Transmission Manual:

Manual gearbox (e.g., KM220, KM221 series), clutch system, driveshafts, differentials.

Transmission Automatic:

Automatic transmission (e.g., W4A series), torque converter, transmission control module (TCM), hydraulic systems.

Drivetrain:

Transfer case (4WD models), propeller shafts, axles, wheel hubs, constant velocity (CV) joints.

Suspension:

Front suspension (independent torsion bar or double wishbone depending on variant), rear suspension (leaf springs), shock absorbers, springs, bushings, alignment specifications.

Steering:

Power steering system, steering gear, steering column, tie rods, power steering pump and reservoir.

Brakes:

Front disc brakes, rear drum or disc brakes, hydraulic system, brake lines, master cylinder, brake booster, parking brake, ABS system (if equipped).

Electrical System General:

Lighting system (headlights, taillights, interior), wiring diagrams for all circuits, fuse box layouts, relay functions, battery system.

Body And Chassis:

Frame construction, body panels, doors, windows, glass, interior trim, seats, bumpers, towing information.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant charging, component replacement (compressor, condenser, evaporator).

Fuel System:

Fuel tanks, fuel pumps, fuel lines, fuel filters, fuel injectors (diesel and petrol).

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication points, belt inspections and replacement.

Engine Repair:

Engine overhaul, piston and ring replacement, bearing replacement, valve adjustment, cylinder head gasket replacement, timing belt/chain replacement.

Transmission Repair:

Clutch replacement, gearbox overhaul, automatic transmission rebuild, seal and gasket replacement.

Drivetrain Repair:

Transfer case servicing, CV joint replacement, axle seal replacement, differential service.

Brake System Repair:

Brake pad/shoe replacement, brake rotor/drum replacement, brake fluid flush, caliper/wheel cylinder overhaul, ABS system diagnostics and repair.

Electrical Troubleshooting:

Diagnostic procedures for all electrical circuits, component testing using multimeters and oscilloscopes, wiring harness repair.

Suspension And Steering Repair:

Shock absorber replacement, ball joint and tie rod end replacement, power steering pump replacement, steering gear adjustment.

Body And Interior Repair:

Door lock mechanism repair, window regulator replacement, interior panel removal and installation, bumper repair, rust prevention.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and uncommon problems, fault code interpretation (OBD-I/OBD-II depending on region/year).

Torque Specifications:

Detailed torque values for all fasteners across all major systems.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic fluid changes and inspections to full engine, transmission, and drivetrain overhauls.

Diagnostic Capability:

Advanced: Includes wiring diagrams, component testing procedures, and troubleshooting trees for complex electronic and mechanical issues.

Special Tools:

Lists and descriptions of special tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for easy navigation of topics.

Print Quality

Graphics Resolution:

High-resolution diagrams, illustrations, and photographs for clarity.

Layout:

Organized logically by system with clear headings, subheadings, and index.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Diesel Engine Family:

4D56 (SOHC, 8-valve or 16-valve common rail in later models), 4M40 (SOHC, 8-valve, direct injection turbo diesel).

Petrol Engine Family:

4G63 (DOHC, 16-valve), 6G72 (SOHC, 24-valve V6).

Performance

4D56 16V Di Turbo Diesel Hp:

Approx. 114 hp to 133 hp (depending on configuration and market).

4D56 16V Di Turbo Diesel Torque:

Approx. 200 lb-ft to 230 lb-ft.

4M40 Turbo Diesel Hp:

Approx. 103 hp to 114 hp.

4M40 Turbo Diesel Torque:

Approx. 177 lb-ft to 200 lb-ft.

4G63 Petrol Hp:

Approx. 133 hp.

4G63 Petrol Torque:

Approx. 135 lb-ft.

6G72 V6 Petrol Hp:

Approx. 180 hp.

6G72 V6 Petrol Torque:

Approx. 200 lb-ft.

Fuel System

Diesel Injection Type:

Indirect Injection (4M40), Direct Injection (4D56 common rail later models).

Petrol Injection Type:

Multi-Point Fuel Injection (MPI).

Engine Codes Specific

Common Diesel Engine:

Common Petrol Engine:

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed automatic transmission.

Features

4Wd System:

Part-time 4WD system with selectable 2WD/4WD High/4WD Low, often with Super Select 4WD system in higher trims.

Clutch Type:

Hydraulically operated dry single-plate clutch.

Fluid Specs

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for exact specification).

Automatic Transmission Fluid:

DIAQueen ATF-SP II M or equivalent (refer to manual for exact specification).

📐 Dimensions

Exterior

Overall Length:

Varies by cab type and bed length, typically 4,500 - 5,000+ mm.

Overall Width:

Approx. 1,690 - 1,775 mm.

Overall Height:

Approx. 1,600 - 1,700 mm.

Cargo

Bed Length:

Varies by configuration (e.g., ~1,800 mm for long bed, ~1,300 mm for short bed).

Weights

Curb Weight:

Approx. 1,500 - 1,900 kg, depending on configuration.

Gross Vehicle Weight Rating Gvw:

Approx. 2,500 - 3,000 kg.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Varies by market and year; generally rated as acceptable for its era, but not to the stringent standards of modern vehicles.

Active Features

Optional on many models, standard on some higher trims.

Limited Slip Differential:

Available on some variants, particularly with 4WD.

Passive Features

Airbags:

Driver airbag standard on many models; passenger airbag optional or standard on higher trims.

Seatbelts:

Three-point seatbelts, often with pre-tensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio, CD player, cassette player in higher trims. Aftermarket head units are common upgrades.

Speakers:

Typically 2 or 4 speakers, depending on cabin configuration.

Driver Assistance

Parking Assistance:

Rear parking sensors were a rare option or aftermarket addition.

Cruise Control:

Available on higher trim levels, particularly with automatic transmissions.

Connectivity

Usb Aux Input:

Not standard; typically requires aftermarket installation.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendations).

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Every 20,000 - 40,000 km or as needed based on inspection.

Fuel Filter Replacement Diesel:

Every 40,000 - 60,000 km (critical for diesel longevity).

Timing Belt Replacement:

For 4G63 (petrol), typically 90,000 - 105,000 km or 7 years. 4D56 and 4M40 (diesel) may use timing chains or belts, consult manual for specifics.

Fluid Specifications

Engine Oil Specification:

API SG/SH/SJ or higher, SAE 10W-30, 15W-40, or 20W-50 depending on climate (refer to manual).

Coolant Specification:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze with corrosion inhibitors.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

DEXRON II or III ATF, or specific Mitsubishi power steering fluid.

Known Issues

Diesel Injector Pump:

Early indirect injection diesel pumps (4M40) can be sensitive to fuel quality.

Rear Leaf Springs:

Can fatigue and sag over time, especially under heavy loads or with age.

Turbocharger Wear:

Turbo units on diesel engines can experience wear or failure if oil changes are neglected or if subjected to extreme conditions.

Suspension Bushings:

Wear in suspension and steering bushings can lead to noise and imprecise handling.

Exhaust Gas Recirculation Egr Valve:

Can become clogged with carbon deposits in diesel models, affecting performance.

📚 Vehicle History

Brand Heritage

Mitsubishi Truck Legacy:

Mitsubishi has a long history of producing rugged and reliable pickup trucks dating back to models like the Mitsubishi Forte and the earlier generations of the L200/Triton.

Model Evolution

L200 Generations:

This fourth generation (K70/K60) represented a significant update from the previous model, featuring improved styling, a more refined interior, and enhanced powertrain options.

Facelifts:

The 1997-2005 period likely covers the facelifted versions of the third generation or the early part of the fourth generation, depending on specific market introductions. The manual's coverage suggests a focus on the K70/K60 series which ran from 1996 to 2006, with updates during that period.

Production

Manufacturing Locations:

Primarily manufactured in Thailand by Mitsubishi Motors Thailand (MMTH), and also in other global assembly plants.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific awards for this exact year range are less documented for global platforms, the L200/Triton consistently receives accolades in various markets for its value, reliability, and off-road capability, often winning 'Pickup of the Year' titles in specific regional publications.

Ratings

Durability Rankings:

Consistently ranks well in owner surveys and reliability indices for its segment, particularly for its robust drivetrain and chassis.