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Mitsubishi Triton L200 1996-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Triton / L200 Generation: Third Generation (K60/K70 series) Production Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: K60 (2WD), K70 (4WD) 👋 Introduction Market Position Segment: Compact to Mid-size Pickup Truck (often categorized with mid-size due to capability) Target Audience: Commercial users, off-road enthusiasts, utility buyers, and general consumers seeking ruggedness and versatility. Competitive Analysis Key Competitors: Toyota Hilux, Nissan Navara (Frontier), Ford Ranger, Isuzu D-Max, Chevrolet Colorado. Key Features Manual Value Proposition: Provides dealership-level repair information, enabling owners and independent mechanics to perform all maintenance and repairs accurately and efficiently, saving significant costs. Vehicle Strengths: Renowned for durability, reliability, off-road capability (especially 4WD models), and robust construction. 📋 Manual Details Coverage Areas Regions Covered: Global (specific to markets where Triton/L200 were sold, common across major regions) Vehicle Types: Pickup Truck (Single Cab, Double Cab, Club Cab) Page Count Estimated Page Count: Extensive (typical for full service manuals, likely over 1000 pages) Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, component inspection, timing, cooling system, lubrication system. Engine Electrical: Ignition system, starting system, charging system, sensors, actuators, engine control module (ECM) troubleshooting. Emission Control: Emission control systems, exhaust gas recirculation (EGR), catalytic converter, evaporative emission control (EVAP). Fuel System: Fuel injection system (MPI, DI for diesel), fuel pump, injectors, fuel filter, fuel tank, diagnostics. Clutch System: Clutch assembly, hydraulic system, release bearing, clutch pedal adjustment. Manual Transmission: Gearbox disassembly, assembly, component replacement, fluid specifications, troubleshooting. Automatic Transmission: Transmission operation, hydraulic control, torque converter, solenoids, valve body, fluid specifications, diagnostics. Driveshaft Axle: Driveshaft removal, installation, universal joints, CV joints, differential, axle shafts. Suspension System: Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment specifications. Steering System: Steering gear, power steering pump, steering linkage, wheel alignment. Restraint System: Seat belts, airbags (SRS) system inspection and replacement (cautionary notes provided). Brake System: Front and rear brakes (disc/drum), ABS system, hydraulic lines, master cylinder, brake fluid specifications, bleeding procedures. Body Interior Exterior: Body panel removal and installation, door mechanisms, glass, interior trim, seats, bed liner. Body Electrical: Lighting systems, interior/exterior lights, power windows, central locking, instrument cluster, horn, wipers, mirrors. HVAC: Heating, ventilation, and air conditioning system (HVAC) components, refrigerant handling, diagnosis. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, brake pad/shoe replacement, spark plug replacement. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for various systems. Repair Procedures: Detailed step-by-step instructions for component removal, repair, and installation. Wiring Schematics: Complete electrical wiring diagrams for all vehicle systems. Diagnostic Information: OBD-II codes interpretation, sensor data analysis, specific component testing procedures. Technical Depth Depth: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and body repairs). 📊 Manual Specifications File Format Quality: High Resolution, Searchable PDF Print Quality Printability: Yes, all pages printable for garage use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: Typically included 4G64 2.4L (Petrol), 4G63 2.0L (Petrol), 4D56 2.5L Diesel, 4M40 2.8L Diesel (Turbocharged variants common). Performance Typical Horsepower: Petrol: 110-140 HP; Diesel: 90-130 HP (Turbo Diesels higher) Typical Torque: Petrol: 180-200 Nm; Diesel: 200-250 Nm (Turbo Diesels higher) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) for gasoline; Direct Injection (DI) for diesel engines. Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant) – specification usually requires a 50/50 mix with distilled water. 🔧 Transmission Standard Transmission Options: 5-speed Manual Transmission (R5Mxx series); 4-speed Automatic Transmission (V4Axx series). Optional Drive Type: 2WD (RWD); 4WD (Part-time transfer case, often with Super Select 4WD system). Features Manual Transmission Fluid: API GL-4 or GL-5 gear oil, viscosity typically 75W-90. Automatic Transmission Fluid: Mitsubishi SP-II or equivalent ATF. 📐 Dimensions Exterior Wheelbase Mm: Approximately 3000 mm for Double Cab models (varies by configuration). Overall Length Mm: Approximately 4850-5000 mm (varies by cabin and bed configuration). Weights Curb Weight Kg: Approximately 1600-1850 kg (varies by engine, drivetrain, and body style). Gross Vehicle Weight Rating Kg: Typically around 2500-2700 kg. 🛡️ Safety Features Ratings Crash Test Results: Variable by region and specific test; generally considered robust for its class but may not meet modern stringent standards without specific market upgrades. Active Features Braking System: Front ventilated discs, rear drums common. ABS available on higher trims and later models. Passive Features Airbags: Driver and passenger airbags standard on many later models or as an option. Seat Belts: 3-point ELR seatbelts with pretensioners and force limiters for front seats. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette or CD player, often with 2 or 4 speakers. Higher trims might offer better sound systems. Display: Simple monochrome display for...
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Mitsubishi Triton L200 1996-2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Triton / L200
Generation:
Third Generation (K60/K70 series)
Production Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Chassis Codes:
K60 (2WD), K70 (4WD)
👋 Introduction
Market Position
Segment:
Compact to Mid-size Pickup Truck (often categorized with mid-size due to capability)
Target Audience:
Commercial users, off-road enthusiasts, utility buyers, and general consumers seeking ruggedness and versatility.
Competitive Analysis
Key Competitors:
Toyota Hilux, Nissan Navara (Frontier), Ford Ranger, Isuzu D-Max, Chevrolet Colorado.
Key Features
Manual Value Proposition:
Provides dealership-level repair information, enabling owners and independent mechanics to perform all maintenance and repairs accurately and efficiently, saving significant costs.
Vehicle Strengths:
Renowned for durability, reliability, off-road capability (especially 4WD models), and robust construction.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specific to markets where Triton/L200 were sold, common across major regions)
Vehicle Types:
Pickup Truck (Single Cab, Double Cab, Club Cab)
Page Count
Estimated Page Count:
Extensive (typical for full service manuals, likely over 1000 pages)
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, component inspection, timing, cooling system, lubrication system.
Engine Electrical:
Ignition system, starting system, charging system, sensors, actuators, engine control module (ECM) troubleshooting.
Emission Control:
Emission control systems, exhaust gas recirculation (EGR), catalytic converter, evaporative emission control (EVAP).
Fuel System:
Fuel injection system (MPI, DI for diesel), fuel pump, injectors, fuel filter, fuel tank, diagnostics.
Clutch System:
Clutch assembly, hydraulic system, release bearing, clutch pedal adjustment.
Manual Transmission:
Gearbox disassembly, assembly, component replacement, fluid specifications, troubleshooting.
Automatic Transmission:
Transmission operation, hydraulic control, torque converter, solenoids, valve body, fluid specifications, diagnostics.
Driveshaft Axle:
Driveshaft removal, installation, universal joints, CV joints, differential, axle shafts.
Suspension System:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment specifications.
Steering System:
Steering gear, power steering pump, steering linkage, wheel alignment.
Restraint System:
Seat belts, airbags (SRS) system inspection and replacement (cautionary notes provided).
Brake System:
Front and rear brakes (disc/drum), ABS system, hydraulic lines, master cylinder, brake fluid specifications, bleeding procedures.
Body Interior Exterior:
Body panel removal and installation, door mechanisms, glass, interior trim, seats, bed liner.
Body Electrical:
Lighting systems, interior/exterior lights, power windows, central locking, instrument cluster, horn, wipers, mirrors.
HVAC:
Heating, ventilation, and air conditioning system (HVAC) components, refrigerant handling, diagnosis.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, brake pad/shoe replacement, spark plug replacement.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for various systems.
Repair Procedures:
Detailed step-by-step instructions for component removal, repair, and installation.
Wiring Schematics:
Complete electrical wiring diagrams for all vehicle systems.
Diagnostic Information:
OBD-II codes interpretation, sensor data analysis, specific component testing procedures.
Technical Depth
Depth:
Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and body repairs).
📊 Manual Specifications
File Format
Quality:
High Resolution, Searchable PDF
Print Quality
Printability:
Yes, all pages printable for garage use.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Typically included 4G64 2.4L (Petrol), 4G63 2.0L (Petrol), 4D56 2.5L Diesel, 4M40 2.8L Diesel (Turbocharged variants common).
Performance
Typical Horsepower:
Petrol: 110-140 HP; Diesel: 90-130 HP (Turbo Diesels higher)
Typical Torque:
Petrol: 180-200 Nm; Diesel: 200-250 Nm (Turbo Diesels higher)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) for gasoline; Direct Injection (DI) for diesel engines.
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant) – specification usually requires a 50/50 mix with distilled water.
🔧 Transmission
Standard
Transmission Options:
5-speed Manual Transmission (R5Mxx series); 4-speed Automatic Transmission (V4Axx series).
Optional
Drive Type:
2WD (RWD); 4WD (Part-time transfer case, often with Super Select 4WD system).
Features
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, viscosity typically 75W-90.
Automatic Transmission Fluid:
Mitsubishi SP-II or equivalent ATF.
📐 Dimensions
Exterior
Wheelbase Mm:
Approximately 3000 mm for Double Cab models (varies by configuration).
Overall Length Mm:
Approximately 4850-5000 mm (varies by cabin and bed configuration).
Weights
Curb Weight Kg:
Approximately 1600-1850 kg (varies by engine, drivetrain, and body style).
Gross Vehicle Weight Rating Kg:
Typically around 2500-2700 kg.
🛡️ Safety Features
Ratings
Crash Test Results:
Variable by region and specific test; generally considered robust for its class but may not meet modern stringent standards without specific market upgrades.
Active Features
Braking System:
Front ventilated discs, rear drums common. ABS available on higher trims and later models.
Passive Features
Airbags:
Driver and passenger airbags standard on many later models or as an option.
Seat Belts:
3-point ELR seatbelts with pretensioners and force limiters for front seats.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette or CD player, often with 2 or 4 speakers. Higher trims might offer better sound systems.
Display:
Simple monochrome display for radio and clock functions. No complex infotainment screens.
Driver Assistance
ABS:
Available on higher trim levels or as an option, particularly on later models.
Connectivity
Auxiliary Inputs:
Rarely equipped with factory AUX or USB inputs; aftermarket solutions common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 10,000 km or 6 months, depending on driving conditions and oil type used (refer to manual for specific intervals).
Timing Belt Replacement:
For petrol engines, typically every 80,000 - 100,000 km. Diesel engines often use timing chains or belts with longer intervals. Crucial to check manual.
Fluid Specifications
Engine Oil Viscosity:
Petrol: 10W-30 or 5W-30 API SG/SH/SJ. Diesel: 15W-40 API CF-4 or CH-4 (turbocharged engines may require specific oils).
Engine Oil Capacity Liters:
Approximately 4.0 - 5.0 liters (depending on engine variant), refer to manual for precise capacity.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Problems:
Rusting on chassis and body panels (especially in coastal or high-humidity areas), potential injector issues on early diesel models, exhaust manifold cracks (4D56), automatic transmission hard shifting.
Preventative Maintenance:
Regular underbody washing, rustproofing treatments, diligent fluid changes, and monitoring of exhaust system are recommended.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi has a long history in producing robust and capable pickup trucks, with the L200/Triton lineage dating back to the 1970s.
Model Evolution
Evolution:
This third generation represented a significant step forward in styling and comfort compared to previous models, solidifying its reputation as a reliable workhorse and adventure vehicle.
Production
Manufacturing Locations:
Primarily Japan, with significant production also occurring in Thailand and other global assembly plants.
🏆 Awards & Recognition
Recognitions
Typical Accolades:
While specific annual awards might be scarce for this era, the Triton/L200 consistently earned a reputation in the automotive press and among owners for its durability and value for money in the utility and pickup truck segments.
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