Mitsubishi L200 Triton 1996-2004 Workshop Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Triton Generation: Fourth Generation (KA/KB series) Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: KA4T, KB4T (common for this era) 👋 Introduction Market Position Segment: Compact Pickup Truck / Sport Utility Vehicle (SUV-like variants exist) Target Audience: Professionals and DIY enthusiasts looking for in-depth repair and maintenance information Competitive Analysis Competitors: Toyota Hilux/Tacoma, Nissan D22/D40 Navara/Frontier, Ford Ranger, Isuzu D-Max Key Features Manual Type: Authoritative, manufacturer-derived information Delivery: Instant digital access Utility: Enables DIY repairs and preventative maintenance, reducing labor costs 📋 Manual Details Coverage Areas Primary Markets: Global (based on common availability of this generation) Page Count Estimated Page Count: Hundreds of pages (typical for a comprehensive workshop manual) Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, and repair of gasoline and diesel engines (specific engines to be confirmed by user based on vehicle) Transmission: Manual and automatic transmission service, repair, and overhaul procedures Drivetrain: Front-wheel drive, rear-wheel drive, and four-wheel drive (4WD) systems, including differentials, driveshafts, and transfer case Suspension: Front and rear suspension components, alignment specifications, and repair procedures Steering: Power steering system diagnosis and repair, steering gear, and components Brakes: Front and rear brake systems (disc/drum), ABS, and related components Electrical: Comprehensive electrical system coverage, including wiring diagrams, lighting, ignition, charging, starting, and accessories Body: Body panels, doors, windows, interior trim, and exterior components HVAC: Heating, ventilation, and air conditioning (HVAC) system service and repair Fuel System: Fuel delivery, injection systems, and fuel tank service Cooling System: Radiator, cooling fans, thermostat, and coolant system service Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipes Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, lubrication, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon faults across all systems Repair Instructions: Step-by-step repair procedures for major components and systems Overhaul Procedures: Detailed instructions for engine, transmission, and differential rebuilds Wiring Diagrams: Comprehensive electrical wiring schematics for all circuits and components Diagnostics: On-board diagnostics (OBD-II) information and fault code interpretation (where applicable) Specifications: Torque specifications, clearances, fluid capacities, and other critical data Technical Depth Depth: Professional-grade, covering everything from routine maintenance to complete engine and transmission rebuilds 📊 Manual Specifications File Format Format: PDF Searchable: Yes (implied by PDF format, but not explicitly stated as OCR'd text) Print Quality Printable: Full Printable Zoom Functionality: Yes Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements Reader Software: Adobe PDF Reader Extraction Software: WinRAR (or similar decompression utility) Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Potential Engines: 2.5L Diesel (4D56, 4M40), 2.8L Diesel (4M40), 3.0L Diesel (4M41), 2.4L Petrol (4G64), 3.0L Petrol (6G72 V6). Specific engine availability varies by market. Performance Horsepower Range: Approx. 90-130 HP (Diesel), 120-140 HP (Petrol V6) - Varies by specific engine and tune Torque Range: Approx. 170-260 Nm (Diesel), 200-240 Nm (Petrol V6) - Varies by specific engine and tune Fuel System Injection Type: Indirect Injection (IDI) or Direct Injection (DI) for diesel; Multi-point Fuel Injection (MPI) for petrol Engine Management ECM: Engine Control Module (ECM) or Engine Control Unit (ECU) for fuel, ignition, and emissions management 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (MT) Optional Optional Transmission: 4-speed Automatic Transmission (AT) - Availability varies by engine and market Features Drivetrain Options: RWD (2WD) and 4WD (Part-time 4WD system with transfer case) 📐 Dimensions Exterior Body Styles: Single Cab, Extended Cab (Club Cab), Double Cab Bed Length Options: Multiple bed lengths available depending on cab configuration Weights Gross Vehicle Weight Rating: Typically in the 2500-3000 kg range, varies by configuration and engine 🛡️ Safety Features Ratings Crash Test Results: Varies significantly by market and specific testing agency for this era. Generally, earlier models had less advanced safety features. Active Features ABS: Anti-lock Braking System (ABS) available on higher trims or as an option Passive Features Airbags: Driver and passenger airbags typically available on later models or higher trims Seatbelts: 3-point seatbelts with pretensioners (front) 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player or CD player. Speaker configurations vary by trim. Navigation: Rarely offered, if at all, on base models of this generation. Aftermarket units were common. Driver Assistance Cruise Control: Available on higher trim levels or as an option. Connectivity Power Accessories: Power windows, power door locks, and power mirrors were available on higher trim levels. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendations) Air Filter Replacement: Every 20,000-40,000 km or as needed based on dust exposure Fuel Filter Replacement: Every 30,000-60,000 km for...
Diagnostic procedures for common and uncommon faults across all systems
Repair Instructions:
Step-by-step repair procedures for major components and systems
Overhaul Procedures:
Detailed instructions for engine, transmission, and differential rebuilds
Wiring Diagrams:
Comprehensive electrical wiring schematics for all circuits and components
Diagnostics:
On-board diagnostics (OBD-II) information and fault code interpretation (where applicable)
Specifications:
Torque specifications, clearances, fluid capacities, and other critical data
Technical Depth
Depth:
Professional-grade, covering everything from routine maintenance to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Yes (implied by PDF format, but not explicitly stated as OCR'd text)
Print Quality
Printable:
Full Printable
Zoom Functionality:
Yes
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
Reader Software:
Adobe PDF Reader
Extraction Software:
WinRAR (or similar decompression utility)
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Potential Engines:
2.5L Diesel (4D56, 4M40), 2.8L Diesel (4M40), 3.0L Diesel (4M41), 2.4L Petrol (4G64), 3.0L Petrol (6G72 V6). Specific engine availability varies by market.
Performance
Horsepower Range:
Approx. 90-130 HP (Diesel), 120-140 HP (Petrol V6) - Varies by specific engine and tune
Torque Range:
Approx. 170-260 Nm (Diesel), 200-240 Nm (Petrol V6) - Varies by specific engine and tune
Fuel System
Injection Type:
Indirect Injection (IDI) or Direct Injection (DI) for diesel; Multi-point Fuel Injection (MPI) for petrol
Engine Management
ECM:
Engine Control Module (ECM) or Engine Control Unit (ECU) for fuel, ignition, and emissions management
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (MT)
Optional
Optional Transmission:
4-speed Automatic Transmission (AT) - Availability varies by engine and market
Features
Drivetrain Options:
RWD (2WD) and 4WD (Part-time 4WD system with transfer case)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab
Bed Length Options:
Multiple bed lengths available depending on cab configuration
Weights
Gross Vehicle Weight Rating:
Typically in the 2500-3000 kg range, varies by configuration and engine
🛡️ Safety Features
Ratings
Crash Test Results:
Varies significantly by market and specific testing agency for this era. Generally, earlier models had less advanced safety features.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims or as an option
Passive Features
Airbags:
Driver and passenger airbags typically available on later models or higher trims
Seatbelts:
3-point seatbelts with pretensioners (front)
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player or CD player. Speaker configurations vary by trim.
Navigation:
Rarely offered, if at all, on base models of this generation. Aftermarket units were common.
Driver Assistance
Cruise Control:
Available on higher trim levels or as an option.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendations)
Air Filter Replacement:
Every 20,000-40,000 km or as needed based on dust exposure
Fuel Filter Replacement:
Every 30,000-60,000 km for diesel, varies for petrol
Timing Belt Replacement:
For petrol engines with timing belts (e.g., 4G64), typically around 80,000-100,000 km or 5-7 years. Diesel engines may use timing chains.
Fluid Specifications
Engine Oil Grade:
API CD/CE/CF or higher for diesel, API SG/SH/SJ for petrol. Viscosity grades commonly 10W-30 or 15W-40 (diesel), 10W-30 or 5W-30 (petrol). Refer to manual for exact specs.
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Mt:
GL-4 or GL-5 gear oil, viscosity varies (e.g., 75W-90, 80W-90)
Transmission Fluid At:
ATF SP-II M or SP-III (refer to manual for exact specification)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Problems:
Rust on chassis and body panels (especially in coastal or high-salt areas), wear in suspension components (ball joints, bushings), injector pump issues (diesel), turbocharger wear (turbo diesel models), minor electrical gremlins.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi has a long history of producing robust trucks and SUVs, with the L200/Triton being a cornerstone of their global pickup truck offerings.
Model Evolution
Fourth Generation:
The KA/KB generation represented a significant redesign from its predecessor, featuring more modern styling and improved comfort and performance.
Production
Manufacturing Locations:
Primarily manufactured in Thailand (Laem Chabang Plant) for global markets, with potential regional assembly.
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