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Mitsubishi Warrior Sportero Hunter Truck Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 / Triton / Strada (Sportero) Generation Generation Name: Fourth Generation (KA/KB) Codes Chassis Codes: KA4T, KB4T 👋 Introduction Market Position Vehicle Segment: Mid-size pickup truck (Ute/Bakkie). Competitive Analysis Competitors Era: Ford Ranger, Toyota Hilux, Isuzu D-Max, Nissan Navara, Chevrolet Colorado/Isuzu D-Max (global variants). Key Features Vehicle Appeal: Robust chassis, capable off-road, durable powertrains, utility focused. Manual Value Proposition Diy Savings: Enables owners to perform maintenance and repairs, saving significant costs on labor. Information Quality: Provides clear, step-by-step instructions with pictures for ease of understanding. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015 Regions Implied: Global (Sportero name often used in South Africa and other markets) Page Count Estimated Page Count: Comprehensive (Exact number not provided, but implied to be extensive for 'Complete Workshop Service Repair Manual') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (mechanical aspects), intake and exhaust systems, timing system. Engine Management: Fuel injection control, ignition system, emissions control, electronic engine diagnostics, sensor and actuator testing, ECU overview. Transmission Manual: Manual gearbox overhaul, clutch system, shift linkage, transfer case (if applicable to models covered). Transmission Automatic: Automatic gearbox overhaul, torque converter, valve body, electronic controls, fluid cooler. Drivetrain: Driveshafts, differentials (front and rear), axles, hubs, wheel bearings, 4WD system operation and servicing. Suspension: Front suspension (e.g., double wishbone), rear suspension (e.g., leaf springs), shock absorbers, springs, bushings, alignment specifications. Steering: Power steering system, steering rack/box, steering column, power steering pump, fluid, linkage. Brakes: Front and rear brake systems (disc/drum), hydraulic components (master cylinder, calipers, wheel cylinders, brake lines), parking brake, ABS system (if equipped), bleeding procedures. Electrical System: Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module. Body And Chassis: Body panel repair, doors, hood, tailgate, bumpers, interior trim, chassis frame inspection and repair. HVAC: Heating, Ventilation, and Air Conditioning system service, refrigerant handling, component replacement (compressor, condenser, evaporator). Safety Systems: Airbag system service and diagnostics, seat belt mechanisms. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant flush, brake fluid replacement, lubrication points. Troubleshooting: Diagnostic procedures for various systems, common fault finding, symptom-based troubleshooting guides. Repair Overhaul: Complete engine rebuilds, transmission overhaul, differential rebuild, suspension component replacement, brake caliper and master cylinder replacement, steering rack replacement. Electrical Diagnostics: Tracing electrical faults, testing sensors and actuators, reading wiring diagrams, component testing. Bodywork: Panel alignment, door adjustment, glass replacement, trim fitting. Technical Depth Depth: Comprehensive from basic maintenance to complete component overhaul and diagnostics. Diagnostic Tools: Details on diagnostic connectors and general procedures, though specific scan tool data might be limited in general manuals. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable (standard for quality PDF manuals). Print Quality Print Option: Printable (allows users to print individual pages, chapters, or the entire manual). Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Compatibility Device Compatibility: All PC & MAC Computers, tablets, mobile phones. Software Requirements Required Software: Adobe Reader (free download available). ⚙️ Engine Specifications Primary Engine Engine Family: 4D56 (Common diesel variant), 6G72 (V6 Petrol variant possible but less common in this generation for export models named Sportero/Hunter). Diesel Engine Variant: 4D56: 2.5L (2477cc) SOHC 16-valve Intercooled Turbocharged Diesel. Power output typically 133-178 PS (131-176 hp) depending on tune and intercooler setup. Performance Torque Diesel: Approx. 314-400 Nm (231-295 lb-ft) for the 4D56 variants. Fuel System Fuel Delivery Diesel: Common Rail Direct Injection (CRDI). Cooling System Coolant Type: Proprietary long-life coolant (e.g., Mitsubishi Super Long Life Coolant AZYL). Lubrication System Engine Oil Capacity: Approx. 6.5 - 7.5 liters (check specific engine variant in manual for exact figure). Maintenance Timing Belt Or Chain: Timing Belt (for 4D56 engines, typically requires replacement at specified intervals). 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission. Optional Transmission Type: 4-speed or 5-speed Automatic Transmission (depending on market and trim). Features Drivetrain Options: Part-time 4WD with selectable 2WD/4WD modes, often including a low-range gear (4LLc). Fluid Specs Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 75W-85 (check specific recommendation). Automatic Transmission Fluid: Mitsubishi SP III or equivalent ATF. 📐 Dimensions Exterior Body Styles: Single Cab, Extended Cab (Club Cab), Double Cab. Wheelbase Mm: Approx. 3000 mm (varies slightly by cab type). Weights Gross Vehicle Weight Rating Kg: Typically around 2,500 - 3,000 kg depending on configuration. 🛡️ Safety Features Ratings Crash Test Ratings: Varies by region and specific test conducted. Generally, modern pickups from this era received moderate ratings; refer to specific regional NCAP reports. Active Features Braking...
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Mitsubishi Warrior Sportero Hunter Truck Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200 / Triton / Strada (Sportero)
Generation
Generation Name:
Fourth Generation (KA/KB)
Codes
Chassis Codes:
KA4T, KB4T
👋 Introduction
Market Position
Vehicle Segment:
Mid-size pickup truck (Ute/Bakkie).
Competitive Analysis
Competitors Era:
Ford Ranger, Toyota Hilux, Isuzu D-Max, Nissan Navara, Chevrolet Colorado/Isuzu D-Max (global variants).
Key Features
Vehicle Appeal:
Robust chassis, capable off-road, durable powertrains, utility focused.
Manual Value Proposition
Diy Savings:
Enables owners to perform maintenance and repairs, saving significant costs on labor.
Information Quality:
Provides clear, step-by-step instructions with pictures for ease of understanding.
📋 Manual Details
Coverage Areas
Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
Regions Implied:
Global (Sportero name often used in South Africa and other markets)
Page Count
Estimated Page Count:
Comprehensive (Exact number not provided, but implied to be extensive for 'Complete Workshop Service Repair Manual')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (mechanical aspects), intake and exhaust systems, timing system.
Engine Management:
Fuel injection control, ignition system, emissions control, electronic engine diagnostics, sensor and actuator testing, ECU overview.
Transmission Manual:
Manual gearbox overhaul, clutch system, shift linkage, transfer case (if applicable to models covered).
Transmission Automatic:
Automatic gearbox overhaul, torque converter, valve body, electronic controls, fluid cooler.
Drivetrain:
Driveshafts, differentials (front and rear), axles, hubs, wheel bearings, 4WD system operation and servicing.
Suspension:
Front suspension (e.g., double wishbone), rear suspension (e.g., leaf springs), shock absorbers, springs, bushings, alignment specifications.
Steering:
Power steering system, steering rack/box, steering column, power steering pump, fluid, linkage.
Brakes:
Front and rear brake systems (disc/drum), hydraulic components (master cylinder, calipers, wheel cylinders, brake lines), parking brake, ABS system (if equipped), bleeding procedures.
Electrical System:
Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module.
Body And Chassis:
Body panel repair, doors, hood, tailgate, bumpers, interior trim, chassis frame inspection and repair.
HVAC:
Heating, Ventilation, and Air Conditioning system service, refrigerant handling, component replacement (compressor, condenser, evaporator).
Safety Systems:
Airbag system service and diagnostics, seat belt mechanisms.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, fuel filter replacement, coolant flush, brake fluid replacement, lubrication points.
Troubleshooting:
Diagnostic procedures for various systems, common fault finding, symptom-based troubleshooting guides.
Repair Overhaul:
Complete engine rebuilds, transmission overhaul, differential rebuild, suspension component replacement, brake caliper and master cylinder replacement, steering rack replacement.
Electrical Diagnostics:
Tracing electrical faults, testing sensors and actuators, reading wiring diagrams, component testing.
Bodywork:
Panel alignment, door adjustment, glass replacement, trim fitting.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete component overhaul and diagnostics.
Diagnostic Tools:
Details on diagnostic connectors and general procedures, though specific scan tool data might be limited in general manuals.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (standard for quality PDF manuals).
Print Quality
Print Option:
Printable (allows users to print individual pages, chapters, or the entire manual).
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Device Compatibility:
All PC & MAC Computers, tablets, mobile phones.
Software Requirements
Required Software:
Adobe Reader (free download available).
⚙️ Engine Specifications
Primary Engine
Engine Family:
4D56 (Common diesel variant), 6G72 (V6 Petrol variant possible but less common in this generation for export models named Sportero/Hunter).
Diesel Engine Variant:
4D56: 2.5L (2477cc) SOHC 16-valve Intercooled Turbocharged Diesel. Power output typically 133-178 PS (131-176 hp) depending on tune and intercooler setup.
Performance
Torque Diesel:
Approx. 314-400 Nm (231-295 lb-ft) for the 4D56 variants.
Fuel System
Fuel Delivery Diesel:
Common Rail Direct Injection (CRDI).
Cooling System
Coolant Type:
Proprietary long-life coolant (e.g., Mitsubishi Super Long Life Coolant AZYL).
Lubrication System
Engine Oil Capacity:
Approx. 6.5 - 7.5 liters (check specific engine variant in manual for exact figure).
Maintenance
Timing Belt Or Chain:
Timing Belt (for 4D56 engines, typically requires replacement at specified intervals).
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission.
Optional
Transmission Type:
4-speed or 5-speed Automatic Transmission (depending on market and trim).
Features
Drivetrain Options:
Part-time 4WD with selectable 2WD/4WD modes, often including a low-range gear (4LLc).
Fluid Specs
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 75W-85 (check specific recommendation).
Automatic Transmission Fluid:
Mitsubishi SP III or equivalent ATF.
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab.
Wheelbase Mm:
Approx. 3000 mm (varies slightly by cab type).
Weights
Gross Vehicle Weight Rating Kg:
Typically around 2,500 - 3,000 kg depending on configuration.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by region and specific test conducted. Generally, modern pickups from this era received moderate ratings; refer to specific regional NCAP reports.
Active Features
Braking System:
Anti-lock Braking System (ABS) available on higher trims.
Passive Features
Airbags:
Driver and front passenger airbags typically standard or optional.
Seatbelts:
Pre-tensioner seatbelts for front occupants.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, potentially MP3 and auxiliary input on later models. Speaker count and quality vary by trim.
Driver Assistance
Traction Control:
Traction Control System (TCS) available on some higher trims, often integrated with ABS.
Connectivity
Usb Aux Ports:
May be present on higher trim levels from mid-life updates.
🔧 Maintenance
Service Intervals
Engine Oil Filter Change Diesel:
Typically every 5,000 - 10,000 km or 6 months (refer to manual for exact interval based on operating conditions).
Timing Belt Replacement:
Generally around 100,000 km or 5-7 years for the 4D56 engine (critical inspection/replacement).
Fuel Filter Replacement:
Typically every 20,000 - 40,000 km for diesel engines.
Fluid Specifications
Engine Oil Spec:
For 4D56 Diesel: API CI-4 or CH-4, SAE 15W-40 or 10W-30 (depending on climate). Consult manual for precise OEM spec.
Brake Fluid Spec:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron III or equivalent ATF, or specific power steering fluid.
Known Issues
Diesel Engine Potential Issues:
Turbocharger issues (if not maintained, e.g., regular oil changes), injector wear, EGR valve clogging, glow plug issues, timing belt failure if not replaced on schedule.
Drivetrain Potential Issues:
Transfer case wear (especially with frequent 4WD use), differential noise.
Suspension Potential Issues:
Worn leaf springs (heavy load usage), worn ball joints and bushings.
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Legacy:
Mitsubishi has a long history of producing durable and capable pickup trucks, dating back to models like the Forte and Colt L200.
Model Evolution
Fourth Gen Debut:
The fourth generation (KA/KB) debuted globally in 2005, introducing a more modern design and improved chassis.
Production
Production Locations:
Primarily manufactured by Mitsubishi Motors Corporation in Thailand, and also in other global assembly plants.
🏆 Awards & Recognition
Recognitions
Award Type:
While specific awards for the 'Warrior Sportero Hunter Truck' variant are not widely documented, the L200/Triton platform generally receives recognition for its durability and capability in various international markets, often winning 'Bakkie of the Year' or similar utility vehicle awards in regions where it's popular.
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