Mitsubishi Triton L200 Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Triton L200 Model Line: Triton / L200 Codes Generation Code: Third Generation (K50/K60/K70) Internal Project Code: K50 Series (for 2WD), K60/K70 Series (for 4WD) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Pickup Truck (often classified as a light commercial vehicle or lifestyle utility vehicle) Competitive Analysis Key Competitors Era: Toyota Hilux/Tacoma, Nissan Navara/Frontier, Ford Ranger, Isuzu D-Max, Holden Rodeo/Colorado (depending on market) Key Features Platform Philosophy: Ruggedness, durability, versatility, and capability for both work and recreational use. Known for its robust chassis and reliable powertrains, especially the diesel engines. Body Styles: Club Cab (extended cab), Double Cab (crew cab), Single Cab (regular cab) and various bed lengths. Also available in 2WD and 4WD configurations. 📋 Manual Details Coverage Areas Applicable Model Years: 1997, 1998, 1999, 2000, 2001, 2002 Market Regions: Global (likely including Australia, Europe, Asia, and other markets where L200 was sold) Page Count Estimated Page Count: Highly variable based on specific engine and drivetrain combinations, likely exceeding 1500 pages for a comprehensive digital manual covering all variants. Manual Type Manual Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Download File Format: RAR (requires WinRAR or compatible extraction utility) Document Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (4D56, 4G63, 4G64, 4M40, 6G72, 6G74 - disassembly, inspection, assembly, timing procedures, component replacement) Engine Lubrication Cooling: Yes (Oil pump, oil filter, oil cooler, water pump, radiator, thermostat, coolant system flush and fill) Engine Fuel Emission Control: Yes (Fuel injection systems (MPI/GDI for petrol, common rail/indirect injection for diesel), fuel pumps, injectors, emission control devices, EGR, catalytic converters) Accelerator Control: Yes (Throttle body, accelerator pedal assembly, cables, cruise control actuators) Fuel Exhaust Systems: Yes (Fuel tank, fuel lines, exhaust manifolds, mufflers, pipes, catalytic converters, turbocharger systems) Transmission Manual: Yes (Clutch operation, manual gearbox disassembly, assembly, inspection, gear shift linkage) Transmission Automatic: Yes (Automatic transmission operation, fluid checks, filter replacement, control systems, common issues) Drivetrain Axles Differential: Yes (Propeller shafts, universal joints, differential carrier disassembly/assembly, axle ratios, hub seals) Front Suspension: Yes (Wishbones, coil springs, shock absorbers, ball joints, sway bars, wheel alignment specifications) Rear Suspension: Yes (Leaf springs (common on many Triton/L200 variants), shock absorbers, U-bolts, axle locating links) Brake System: Yes (Front discs, rear drums/discs, ABS system, brake fluid specifications, bleeding procedures, component replacement) Steering System: Yes (Power steering pump, steering rack/box, tie rods, steering column, lubrication) Restraint System: Yes (Seat belts, airbag system (SRS) diagnostics and component replacement, caution for airbag handling) Body Trim: Yes (Exterior panels, interior trim removal/installation, door mechanisms, glass replacement, body sealing) Heater Air Conditioner: Yes (HVAC system operation, refrigerant types, component replacement (compressor, condenser, evaporator), blower motor, heater core) Electrical System: Yes (Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, ECUs, sensor testing, diagnostics) Electronic Control Unit ECU: Yes (ECU identification, diagnostic trouble codes (DTCs), sensor inputs/outputs, troubleshooting procedures for engine management and other control modules) Procedures Included General Information: Yes (Vehicle identification, safety precautions, jacking and lifting points, torque specifications, fluid types) Maintenance: Yes (Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, basic inspections) Engine Mechanical Repair: Yes (Complete engine rebuilds, piston and ring replacement, cylinder head overhaul, valve seating, crankshaft and bearing replacement) Transmission Repair: Yes (Clutch replacement, manual transmission gearbox rebuilds, automatic transmission servicing and repair) Suspension Steering Repair: Yes (Component replacement, alignment procedures, power steering system repairs) Brake System Repair: Yes (Disc and drum service, caliper and cylinder replacement, ABS bleeding, master cylinder overhaul) Electrical Diagnostics: Yes (Troubleshooting circuits, using multimeter, interpreting wiring diagrams, sensor testing, actuator testing) Bodywork Procedures: Yes (Panel alignment, door glass replacement, weather stripping, basic body repair guidance) HVAC Service: Yes (Refrigerant handling, component replacement, leak detection, flushing) Troubleshooting Guides: Yes (Diagnostic charts for common symptoms across various systems) Technical Depth Diagnostic Capability: Comprehensive (Includes diagnostic charts, DTC interpretations, sensor data analysis, and troubleshooting procedures) Rebuild Procedures: Complete (Covers full disassembly, inspection, measurement, and reassembly for major components like engines and transmissions) Wiring Diagrams: Included (Detailed electrical schematics for all major systems, crucial for electrical troubleshooting) Torque Specifications: Extensive (Precise torque values provided for all critical fasteners across engine, chassis, and bodywork) Illustrations Diagrams: Abundant (Step-by-step diagrams, exploded views, and illustrations to aid in repair procedures) 📊 Manual Specifications File Format Extraction Requirement: WinRAR or compatible (RAR archive) Document Readability: PDF (typically high-resolution for clear viewing and printing) Print Quality Printability: High (Designed to be printed for workshop use, typically in a modular format) Binding Type Digital Format Consideration: N/A (as it's a digital download, but original manuals were often bound) Paper Type Digital Format Consideration: N/A (as it's a digital download, but original manuals were typically printed on durable, matte paper) ⚙️ Engine Specifications Primary Engine Most Common Engine Diesel: 4D56 2.5L Turbo Diesel (SOHC,...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Triton L200

Model Line:

Triton / L200

Codes

Generation Code:

Third Generation (K50/K60/K70)

Internal Project Code:

K50 Series (for 2WD), K60/K70 Series (for 4WD)

👋 Introduction

Market Position

Vehicle Segment:

Compact/Mid-size Pickup Truck (often classified as a light commercial vehicle or lifestyle utility vehicle)

Competitive Analysis

Key Competitors Era:

Toyota Hilux/Tacoma, Nissan Navara/Frontier, Ford Ranger, Isuzu D-Max, Holden Rodeo/Colorado (depending on market)

Key Features

Platform Philosophy:

Ruggedness, durability, versatility, and capability for both work and recreational use. Known for its robust chassis and reliable powertrains, especially the diesel engines.

Body Styles:

Club Cab (extended cab), Double Cab (crew cab), Single Cab (regular cab) and various bed lengths. Also available in 2WD and 4WD configurations.

📋 Manual Details

Coverage Areas

Applicable Model Years:

1997, 1998, 1999, 2000, 2001, 2002

Market Regions:

Global (likely including Australia, Europe, Asia, and other markets where L200 was sold)

Page Count

Estimated Page Count:

Highly variable based on specific engine and drivetrain combinations, likely exceeding 1500 pages for a comprehensive digital manual covering all variants.

Manual Type

Manual Type:

Workshop Manual / Service Manual / Repair Manual

Language

Language:

English

Format

Download File Format:

RAR (requires WinRAR or compatible extraction utility)

Document Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Yes (4D56, 4G63, 4G64, 4M40, 6G72, 6G74 - disassembly, inspection, assembly, timing procedures, component replacement)

Engine Lubrication Cooling:

Yes (Oil pump, oil filter, oil cooler, water pump, radiator, thermostat, coolant system flush and fill)

Engine Fuel Emission Control:

Yes (Fuel injection systems (MPI/GDI for petrol, common rail/indirect injection for diesel), fuel pumps, injectors, emission control devices, EGR, catalytic converters)

Accelerator Control:

Yes (Throttle body, accelerator pedal assembly, cables, cruise control actuators)

Fuel Exhaust Systems:

Yes (Fuel tank, fuel lines, exhaust manifolds, mufflers, pipes, catalytic converters, turbocharger systems)

Transmission Manual:

Yes (Clutch operation, manual gearbox disassembly, assembly, inspection, gear shift linkage)

Transmission Automatic:

Yes (Automatic transmission operation, fluid checks, filter replacement, control systems, common issues)

Drivetrain Axles Differential:

Yes (Propeller shafts, universal joints, differential carrier disassembly/assembly, axle ratios, hub seals)

Front Suspension:

Yes (Wishbones, coil springs, shock absorbers, ball joints, sway bars, wheel alignment specifications)

Rear Suspension:

Yes (Leaf springs (common on many Triton/L200 variants), shock absorbers, U-bolts, axle locating links)

Brake System:

Yes (Front discs, rear drums/discs, ABS system, brake fluid specifications, bleeding procedures, component replacement)

Steering System:

Yes (Power steering pump, steering rack/box, tie rods, steering column, lubrication)

Restraint System:

Yes (Seat belts, airbag system (SRS) diagnostics and component replacement, caution for airbag handling)

Body Trim:

Yes (Exterior panels, interior trim removal/installation, door mechanisms, glass replacement, body sealing)

Heater Air Conditioner:

Yes (HVAC system operation, refrigerant types, component replacement (compressor, condenser, evaporator), blower motor, heater core)

Electrical System:

Yes (Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, ECUs, sensor testing, diagnostics)

Electronic Control Unit ECU:

Yes (ECU identification, diagnostic trouble codes (DTCs), sensor inputs/outputs, troubleshooting procedures for engine management and other control modules)

Procedures Included

General Information:

Yes (Vehicle identification, safety precautions, jacking and lifting points, torque specifications, fluid types)

Maintenance:

Yes (Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, basic inspections)

Engine Mechanical Repair:

Yes (Complete engine rebuilds, piston and ring replacement, cylinder head overhaul, valve seating, crankshaft and bearing replacement)

Transmission Repair:

Yes (Clutch replacement, manual transmission gearbox rebuilds, automatic transmission servicing and repair)

Suspension Steering Repair:

Yes (Component replacement, alignment procedures, power steering system repairs)

Brake System Repair:

Yes (Disc and drum service, caliper and cylinder replacement, ABS bleeding, master cylinder overhaul)

Electrical Diagnostics:

Yes (Troubleshooting circuits, using multimeter, interpreting wiring diagrams, sensor testing, actuator testing)

Bodywork Procedures:

Yes (Panel alignment, door glass replacement, weather stripping, basic body repair guidance)

HVAC Service:

Yes (Refrigerant handling, component replacement, leak detection, flushing)

Troubleshooting Guides:

Yes (Diagnostic charts for common symptoms across various systems)

Technical Depth

Diagnostic Capability:

Comprehensive (Includes diagnostic charts, DTC interpretations, sensor data analysis, and troubleshooting procedures)

Rebuild Procedures:

Complete (Covers full disassembly, inspection, measurement, and reassembly for major components like engines and transmissions)

Wiring Diagrams:

Included (Detailed electrical schematics for all major systems, crucial for electrical troubleshooting)

Torque Specifications:

Extensive (Precise torque values provided for all critical fasteners across engine, chassis, and bodywork)

Illustrations Diagrams:

Abundant (Step-by-step diagrams, exploded views, and illustrations to aid in repair procedures)

📊 Manual Specifications

File Format

Extraction Requirement:

WinRAR or compatible (RAR archive)

Document Readability:

PDF (typically high-resolution for clear viewing and printing)

Print Quality

Printability:

High (Designed to be printed for workshop use, typically in a modular format)

Binding Type

Digital Format Consideration:

N/A (as it's a digital download, but original manuals were often bound)

Paper Type

Digital Format Consideration:

N/A (as it's a digital download, but original manuals were typically printed on durable, matte paper)

⚙️ Engine Specifications

Primary Engine

Most Common Engine Diesel:

4D56 2.5L Turbo Diesel (SOHC, 8-valve, indirect injection, later common rail variants existed in other markets/generations but this manual likely covers earlier turbo-diesel variants)

Most Common Engine Petrol:

6G72 3.0L V6 Petrol (SOHC/DOHC, V6 configuration, known for smooth power delivery)

Performance

4D56 2.5L Turbo Diesel Power Range:

Approx. 90-115 HP (depending on turbo and intercooler specification)

4M40 2.8L Turbo Diesel Power Range:

Approx. 100-125 HP (known for strong low-end torque)

6G72 3.0L V6 Petrol Power Range:

Approx. 140-170 HP

6G74 3.5L V6 Petrol Power Range:

Approx. 170-200 HP (Often featured GDI in later iterations, but early versions may be MPI)

Fuel System

Diesel Fuel System Type:

Indirect Injection (IDI) with turbocharging and intercooling for 4D56/4M40. Earlier versions might lack intercooling. Later 4D56 variants in other generations used Common Rail Direct Injection (CRDi).

Petrol Fuel System Type:

Multi-Point Fuel Injection (MPI) for most engines in this generation. 6G74 may have seen early Gasoline Direct Injection (GDI) applications in some markets towards the end of this generation's run.

Turbocharging

Turbocharged Engines:

4D56 (2.5L), 4G63 (2.0L), 4G64 (2.4L), 4M40 (2.8L)

🔧 Transmission

Standard

Manual Transmission Options:

Typically 5-speed manual transmission (e.g., KM220, W5MG1 variants)

Optional

Automatic Transmission Options:

Yes, typically 4-speed automatic transmissions (e.g., V4A51, F4Axx series)

Features

Drivetrain Options:

2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) with manual or automatic locking hubs/transfer cases. Some 4WD systems may feature Super Select 4WD or Easy Select 4WD depending on trim and market.

📐 Dimensions

Exterior

Body Style Variations:

Single Cab, Club Cab, Double Cab

Wheelbase Range:

Approximately 2800mm - 3000mm (varies by cab and bed configuration)

Weights

Curb Weight Range:

Approximately 1600 kg - 1950 kg (depending on engine, drivetrain, and body style)

Towing Capacity:

Generally rated between 1500 kg and 2500 kg (subject to local regulations and specific model)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Varies significantly by market and testing body (e.g., ANCAP, Euro NCAP). Early models generally had fewer advanced safety features compared to modern vehicles. Likely rated 3-4 stars in its era.

Active Features

Available Active Safety Features:

Anti-lock Braking System (ABS) was optional or standard on higher trims. Limited availability of other advanced driver-assistance systems (ADAS).

Passive Features

Available Passive Safety Features:

Seat belts (front, rear), reinforced passenger safety cell, potential for driver and passenger airbags on higher trims. Side-impact door beams.

💡 Technology Features

Infotainment

Infotainment Features:

Basic by modern standards. Likely included AM/FM radio, cassette or CD player, manual or power windows, manual or automatic climate control. Navigation systems were rare or aftermarket additions.

Driver Assistance

Driver Assistance Features:

Limited to ABS (optional/higher trims) and potentially cruise control. No advanced ADAS like adaptive cruise control, lane keeping assist, or automatic emergency braking.

Connectivity

Connectivity Options:

No integrated smartphone connectivity (Apple CarPlay/Android Auto), Bluetooth, or Wi-Fi. Connectivity was limited to basic audio inputs.

🔧 Maintenance

Service Intervals

Oil Change Interval Diesel:

Typically 5,000 - 10,000 km or 6 months, whichever comes first, depending on driving conditions and oil quality. Always refer to the manual for specific recommendations.

Oil Change Interval Petrol:

Typically 5,000 - 10,000 km or 6 months, whichever comes first. V6 engines may have slightly different requirements.

Timing Belt Replacement:

For engines with timing belts (e.g., some V6 petrol engines, and potentially early diesel variants), replacement intervals are critical, usually around 80,000 - 100,000 km or 5-7 years. Check the manual for specific engine and belt type.

Fluid Specifications

Engine Oil Viscosity Diesel:

Commonly 10W-30 or 10W-40 (API CF or higher for turbo diesels). Specific grade depends on climate. Check manual for exact specification (e.g., API classification).

Engine Oil Viscosity Petrol:

Commonly 10W-30 or 5W-30 (API SG, SH, SJ, or SL for petrol engines). Check manual for exact specification.

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Verify for specific color requirements (e.g., Green).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Always use fresh, sealed fluid.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, typically 75W-90 or 80W-90. Check manual for specific type and capacity.

Transmission Fluid Automatic:

Dexron-II, Dexron-III, or equivalent ATF. Check manual for precise specification and capacity.

Differential Oil Type:

Hypoid gear oil, typically GL-5, viscosity 80W-90 or 75W-140 for heavy-duty use. Verify for LSD if equipped.

Known Issues

Diesel Engine Common Problems:

Turbocharger wear (especially with high mileage or poor maintenance), glow plug issues on cold starts, injection pump wear, potential for head gasket issues on high-mileage examples.

Petrol Engine Common Problems:

V6 engines can be prone to intake manifold gasket leaks, spark plug issues (especially on V6 where access is tight), and coolant leaks (radiator, hoses, water pump).

Suspension Wear:

Leaf springs can sag under heavy loads or over time. Ball joints, tie rod ends, and bushings are common wear items in the front suspension, especially with off-road use.

Electrical Corrosion:

In some climates, particularly coastal areas, electrical connectors and grounds can experience corrosion, leading to intermittent issues.

📚 Vehicle History

Brand Heritage

Mitsubishi Truck Legacy:

Mitsubishi has a long history of producing robust and capable pickup trucks, dating back to models like the Mitsubishi Forte and Mitsubishi Strada. The L200/Triton lineage is a cornerstone of their commercial and utility vehicle offerings.

Model Evolution

Third Generation Development:

The third generation (K50/K60/K70) represented a significant evolution from the second generation, featuring more modern styling, improved chassis dynamics, and a wider range of engine options, including more powerful diesel and V6 petrol variants. It solidified the L200's reputation for durability in challenging conditions.

Production

Manufacturing Locations:

Primary manufacturing typically occurred in Japan, with significant production also in Thailand and other global facilities depending on market demand and regional manufacturing strategies.

🏆 Awards & Recognition

Recognitions

Truck Awards Era:

While specific awards for the 1997-2002 Triton/L200 are difficult to pinpoint without extensive historical data, the model consistently received recognition in its segment for durability, off-road capability, and value for money in various international markets.

Ratings

Ownership Satisfaction Ratings:

Generally strong ownership satisfaction due to its utilitarian nature and reliability, particularly from owners who valued its workhorse capabilities.