1997-2002 Mitsubishi L200 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Generation: Third Generation Codes Platform Code: K50, K60, K70 Series Chassis Type: Pickup Truck / Light Commercial Vehicle 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck / Light Commercial Vehicle (LCV) Key Selling Points: Durability, off-road capability, versatility for work and leisure, relatively simple mechanicals. Competitive Analysis Competitors: Toyota Hilux, Nissan D22 (Navara/Frontier), Ford Ranger (early models), Isuzu D-Max (early models) Key Features Manual Value: Provides essential information for maintenance, diagnostics, and repair, enabling DIY enthusiasts and professional mechanics to service the vehicle effectively. Vehicle Characteristics: Rugged construction, body-on-frame chassis, available in 2WD and 4WD configurations, various body styles (single cab, double cab, chassis cab). 📋 Manual Details Coverage Areas Applicable Model Years: 1997, 1998, 1999, 2000, 2001, 2002 Regions Covered: Global (with emphasis on markets where this generation was prevalent) Page Count Estimated Pages: Approx. 2000+ Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valvetrain Engine Management: Fuel injection system (MPI, GDI where applicable), ignition system, emission control systems, ECU diagnosis Transmission Manual: Clutch, gearbox assembly, shift mechanism, final drive, transfer case (4WD models) Transmission Automatic: Automatic transmission assembly, torque converter, hydraulic control, electronic control unit Drivetrain: Driveshafts, axles, differentials, propeller shafts, CV joints Suspension: Front and rear suspension components, shock absorbers, springs, control arms, stabilizer bars Steering: Steering gear, steering column, power steering system (pump, hoses, rack/box) Brakes: Brake system components (master cylinder, calipers, rotors, drums, lines), ABS (if equipped) Electrical System: Battery, charging system (alternator), starting system (starter), lighting, horn, wipers, power windows, central locking Climate Control: HVAC system, air conditioning, heater core, blower motor, controls Body And Chassis: Body panels, doors, hood, tailgate, bumpers, frame, underbody coatings Interior: Seats, dashboard, trim panels, airbags, seatbelts Diagnostics: OBD-II (On-Board Diagnostics) procedures, trouble code interpretation, diagnostic flowcharts Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic guides for common and uncommon problems, symptom-based troubleshooting charts Repair And Replacement: Detailed step-by-step instructions for component removal, repair, and reinstallation Overhaul: Complete engine and transmission rebuild procedures Electrical Diagnostics: Wiring diagrams, component testing, circuit diagnosis Body Repair: Dent repair, panel replacement, welding procedures, rust prevention Technical Depth Depth: Comprehensive: Covers everything from basic fluid changes to full engine/transmission rebuilds and advanced electrical diagnostics. Detail Level: Professional Technician Level: Includes torque specifications, diagnostic trouble codes (DTCs), and detailed procedural steps. Diagrams And Illustrations: Abundant: Features exploded views, wiring diagrams, schematic diagrams, and step-by-step illustrations. 📊 Manual Specifications File Format Digital Format: PDF Searchable Text: Likely searchable text for easy navigation and keyword lookup. Print Quality Digital Resolution: High-resolution scans suitable for printing individual pages. Binding Type Physical Binding Equivalent: Not applicable (digital download), but equivalent to a professionally bound workshop manual. Paper Type Digital Paper Equivalent: Not applicable (digital download), but quality is intended for professional shop use. ⚙️ Engine Specifications Primary Engine Engine Family: 4G6x (Petrol), 4D5x (Diesel), 4M4x (Diesel) Common Petrol Engine 1: 2.0L SOHC 16V (4G63/4G64 variants) Common Petrol Engine 2: 2.4L SOHC 16V (4G64 variants) Common Diesel Engine 1: 2.5L SOHC 8V Diesel (4D56 variants) Common Diesel Engine 2: 2.8L SOHC 8V Turbo-Diesel (4M40 variants) Common Diesel Engine 3: 3.2L DOHC 16V Turbo-Diesel (4M41 - less common in this generation, might appear in later years/specific markets) Performance Petrol Hp Range: Approx. 110-140 hp Diesel Hp Range: Approx. 85-135 hp (naturally aspirated vs. turbo) Fuel System Petrol Injection Type: Multi-Point Fuel Injection (MPI) Diesel Injection Type: Indirect Injection (IDI) or Direct Injection (DI) depending on engine variant Technical Details Bore Stroke Example: 4G64: 86.5 mm x 86.0 mm Compression Ratio Example: 4G64: 9.0:1; 4D56: 21.0:1 🔧 Transmission Standard Transmission Type Common: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Drivetrain Options: RWD (Rear-Wheel Drive), 4WD (Four-Wheel Drive) with selectable or full-time transfer cases Specifications Gear Ratios: Varies by transmission and model, detailed in manual. Fluid Specifications Manual Gearbox Oil Type: API GL-4 or GL-5, viscosity typically 75W-90 Automatic Transmission Fluid Type: Dexron III or equivalent (refer to manual for exact specification) 📐 Dimensions Exterior Body Styles Offered: Single Cab, Extended Cab (Club Cab), Double Cab Bed Lengths: Short Bed, Long Bed (varies by configuration) Wheelbase: Varies by body style and configuration (e.g., ~3000 mm for Double Cab Long Bed) Weights Curb Weight: Approx. 1500-1900 kg (depending on configuration and engine) Payload Capacity: Typically 800-1200 kg Towing Capacity: Varies significantly by market and configuration, typically up to 2000-2500 kg (braked) 🛡️ Safety Features Ratings Crash Test Results: Limited official ratings for this era and vehicle type in many markets. Likely basic by modern standards. Active Features ABS: Optional on many models, standard on...
Durability, off-road capability, versatility for work and leisure, relatively simple mechanicals.
Competitive Analysis
Competitors:
Toyota Hilux, Nissan D22 (Navara/Frontier), Ford Ranger (early models), Isuzu D-Max (early models)
Key Features
Manual Value:
Provides essential information for maintenance, diagnostics, and repair, enabling DIY enthusiasts and professional mechanics to service the vehicle effectively.
Vehicle Characteristics:
Rugged construction, body-on-frame chassis, available in 2WD and 4WD configurations, various body styles (single cab, double cab, chassis cab).
📋 Manual Details
Coverage Areas
Applicable Model Years:
1997, 1998, 1999, 2000, 2001, 2002
Regions Covered:
Global (with emphasis on markets where this generation was prevalent)
Comprehensive: Covers everything from basic fluid changes to full engine/transmission rebuilds and advanced electrical diagnostics.
Detail Level:
Professional Technician Level: Includes torque specifications, diagnostic trouble codes (DTCs), and detailed procedural steps.
Diagrams And Illustrations:
Abundant: Features exploded views, wiring diagrams, schematic diagrams, and step-by-step illustrations.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchable Text:
Likely searchable text for easy navigation and keyword lookup.
Print Quality
Digital Resolution:
High-resolution scans suitable for printing individual pages.
Binding Type
Physical Binding Equivalent:
Not applicable (digital download), but equivalent to a professionally bound workshop manual.
Paper Type
Digital Paper Equivalent:
Not applicable (digital download), but quality is intended for professional shop use.
⚙️ Engine Specifications
Primary Engine
Engine Family:
4G6x (Petrol), 4D5x (Diesel), 4M4x (Diesel)
Common Petrol Engine 1:
2.0L SOHC 16V (4G63/4G64 variants)
Common Petrol Engine 2:
2.4L SOHC 16V (4G64 variants)
Common Diesel Engine 1:
2.5L SOHC 8V Diesel (4D56 variants)
Common Diesel Engine 2:
2.8L SOHC 8V Turbo-Diesel (4M40 variants)
Common Diesel Engine 3:
3.2L DOHC 16V Turbo-Diesel (4M41 - less common in this generation, might appear in later years/specific markets)
Performance
Petrol Hp Range:
Approx. 110-140 hp
Diesel Hp Range:
Approx. 85-135 hp (naturally aspirated vs. turbo)
Fuel System
Petrol Injection Type:
Multi-Point Fuel Injection (MPI)
Diesel Injection Type:
Indirect Injection (IDI) or Direct Injection (DI) depending on engine variant
Technical Details
Bore Stroke Example:
4G64: 86.5 mm x 86.0 mm
Compression Ratio Example:
4G64: 9.0:1; 4D56: 21.0:1
🔧 Transmission
Standard
Transmission Type Common:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain Options:
RWD (Rear-Wheel Drive), 4WD (Four-Wheel Drive) with selectable or full-time transfer cases
Specifications
Gear Ratios:
Varies by transmission and model, detailed in manual.
Fluid Specifications
Manual Gearbox Oil Type:
API GL-4 or GL-5, viscosity typically 75W-90
Automatic Transmission Fluid Type:
Dexron III or equivalent (refer to manual for exact specification)
📐 Dimensions
Exterior
Body Styles Offered:
Single Cab, Extended Cab (Club Cab), Double Cab
Bed Lengths:
Short Bed, Long Bed (varies by configuration)
Wheelbase:
Varies by body style and configuration (e.g., ~3000 mm for Double Cab Long Bed)
Weights
Curb Weight:
Approx. 1500-1900 kg (depending on configuration and engine)
Payload Capacity:
Typically 800-1200 kg
Towing Capacity:
Varies significantly by market and configuration, typically up to 2000-2500 kg (braked)
🛡️ Safety Features
Ratings
Crash Test Results:
Limited official ratings for this era and vehicle type in many markets. Likely basic by modern standards.
Active Features
ABS:
Optional on many models, standard on some higher trims/later years.
Passive Features
Airbags:
Driver airbag standard on many models, passenger airbag optional/available on later models.
Seat Belts:
Standard front seat belts, rear seat belts on extended/double cabs.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, optional CD player on higher trims or later models.
Driver Assistance
Cruise Control:
Optional on higher trim levels.
Connectivity
Usb Aux:
Not available in the factory system; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used. Refer to manual for exact recommendation.
Air Filter Replacement:
Check every 15,000-30,000 km, replace as needed or at ~50,000 km intervals.
Spark Plug Replacement:
Petrol engines: ~60,000-100,000 km depending on spark plug type (standard vs. platinum/iridium).
Timing Belt Replacement:
For engines with a timing belt (e.g., 4G6x series), typically 80,000-100,000 km or 5-7 years. The 4D5x and 4M4x series often use timing chains which are designed to last the life of the engine but may require tensioner/guide service.
10W-30 or 10W-40 API SJ/SL, often with JASO DL-1 specification for diesel engines.
Coolant Type:
Ethylene glycol based coolant, typically a green or pink concentrate mixed 50/50 with distilled water. Refer to manual for specific Mopar/Chrysler type or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Problems List:
Rocker arm wear (diesel engines), clutch wear, differential whine, rust on body/chassis, exhaust manifold cracks (turbo diesel), starter motor issues, occasional electronic sensor failures.
📚 Vehicle History
Brand Heritage
Mitsubishi Lcfs History:
Mitsubishi has a long history of producing robust and capable trucks and commercial vehicles, dating back to the early 20th century.
Model Evolution
L200 Lineage:
The L200 (also known as Triton, Mighty Max in some markets) is a long-running nameplate for Mitsubishi's pickup trucks, evolving through multiple generations.
Production
Manufacturing Locations:
Primarily Japan, with significant production in Thailand and other global assembly plants.
Production Years
Generation Production Span:
Third generation (K50/K60/K70) ran from approximately 1996 to 2005, with the 1997-2002 period being the core of this manual's coverage.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for this generation might be scarce, the L200/Triton line has consistently been recognized for its utility, reliability, and value in the pickup truck segment globally.
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