Mitsubishi Triton Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Triton / L200 Product Name: Mitsubishi Triton Workshop Service Repair Manual Product Description: Mitsubishi Triton L200 Workshop Service Repair Manual Codes Covered Models: KA4T, KB4T, KB8T Covered Engines Codes: 4D5 SOHC, 4D56, 4M41 Covered Transmission Codes: R5M21, R5MB1, V5MB1, R4AW4, V5A5A 👋 Introduction Market Position Vehicle Segment: Mid-size pickup truck / Utility vehicle. Target Audience: Commercial users, off-road enthusiasts, fleet operators, and DIY mechanics. Competitive Analysis Key Competitors: Toyota Hilux, Ford Ranger, Nissan Navara, Isuzu D-Max, Chevrolet Colorado. Key Features Value Proposition: Known for its robustness, durability, and capable 4x4 systems, often offering a strong value proposition in its segment. Manual Value: Essential for owners and technicians to maintain, diagnose, and repair these vehicles effectively, covering a wide range of models and powertrains. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (likely PDF) Page Count Estimated Page Count: Extensive (typical for comprehensive workshop manuals, often 1000+ pages) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel injection (diesel), emission control, turbocharging (where applicable), engine management system (ECU). Transmission Systems: Manual transmission (R5M21, R5MB1, V5MB1), Automatic transmission (R4AW4, V5A5A) diagnostics, repair, overhaul, fluid specifications, torque converter. Drivetrain Systems: Front and rear axles, differential, driveshafts, propeller shaft, four-wheel drive system operation and repair. Suspension Steering: Front and rear suspension components (coil springs, leaf springs, shock absorbers, control arms), steering gear, power steering system, alignment specifications. Brake Systems: Front and rear brake systems (disc/drum), hydraulic circuits, ABS (Anti-lock Braking System) if equipped, parking brake. Electrical Systems: Battery, charging system (alternator), starting system, ignition system (if applicable to diesel variants), lighting, instrument panel, power windows, central locking, wiring diagrams. HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling. Body Exterior Interior: Body panel repair, doors, hood, tailgate, interior trim, seats, glass replacement. Chassis Frame: Frame inspection, repair, and maintenance. Procedures Included Maintenance Procedures: Routine maintenance tasks, fluid changes, filter replacements, lubrication points, belt inspections and tensioning. Diagnostic Procedures: Troubleshooting guides, fault code interpretation (OBD-II if applicable), symptom-based diagnostics for various systems. Repair Procedures: Step-by-step repair instructions for all major mechanical and electrical components, including disassembly, assembly, and reassembly. Overhaul Rebuild: Detailed procedures for complete engine and transmission overhauls, including component specifications and tolerances. Replacement Procedures: Instructions for replacing wear items and major components such as alternators, starter motors, brake pads, clutch assemblies, and more. Calibration Adjustment: Procedures for adjusting clutch, brakes, and other systems as needed. Technical Depth Depth Of Coverage: Comprehensive (covers everything from basic maintenance to full engine and transmission rebuilds). Wiring Diagrams: Includes detailed electrical system wiring diagrams for various configurations. Torque Specifications: Provides crucial torque specifications for all fasteners to ensure proper assembly and prevent damage. Diagnostic Troubleshooting Charts: Includes structured troubleshooting charts to systematically identify and resolve issues. Component Drawings Illustrations: Features exploded views and detailed illustrations of components for clarity during disassembly and reassembly. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - typically searchable and printable. Print Quality Digital Quality: High resolution, clear text and diagrams for readability. Binding Type Digital Binding: N/A (Digital) Paper Type Digital Paper Type: N/A (Digital) File Features Searchability: Text-searchable for quick access to specific information. Printability: Printable pages for convenient use in a workshop environment. ⚙️ Engine Specifications Primary Engine Engine Displacement 2500: 2.5 Liters (approx. 2500cc) Engine Displacement 3200: 3.2 Liters (approx. 3200cc) Engine 4D56: 2.5L 4-cylinder SOHC turbocharged diesel engine (various power outputs depending on market and specific model). Engine 4M41: 3.2L 4-cylinder DOHC DI-D (Direct Injection Diesel) Common Rail turbocharged diesel engine (known for improved power and refinement over earlier engines). Performance Horsepower Range: Typically ranging from 100 HP to over 170 HP depending on engine variant and market. Torque Range: Torque figures generally between 200 Nm and 400 Nm, maximizing towing and hauling capabilities. Fuel System Fuel Type: Diesel Injection System 4D56: Indirect Injection (ID) or Direct Injection (DI) depending on sub-variant. Injection System 4M41: Common Rail Direct Injection (CRDI) with turbocharging. 🔧 Transmission Standard Standard Transmission Type: Manual Transmission Manual Gearboxes Covered: R5M21 (5-speed manual), R5MB1 / V5MB1 (5-speed manual, often with different transfer case configurations). Optional Optional Transmission Type: Automatic Transmission Automatic Gearboxes Covered: R4AW4 (4-speed automatic), V5A5A (5-speed automatic, typically found on higher specification models). Features Transfer Case Options: Includes coverage for various 4WD (Four-Wheel Drive) systems and transfer cases, including part-time and full-time configurations. Gear Ratios: Manuals will contain specific gear ratios for each transmission and transfer case for accurate performance analysis and repair. Fluid Specifications: Details specific automatic transmission fluid (ATF) and manual gearbox oil types and capacities. 📐 Dimensions Exterior Body Styles: Single Cab, Extended/Club Cab, Double Cab. Wheelbase Range: Varies by body style and configuration, typically between 3000mm and 3300mm. Overall Length Range: Varies by...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Triton / L200

Product Name:

Mitsubishi Triton Workshop Service Repair Manual

Product Description:

Mitsubishi Triton L200 Workshop Service Repair Manual

Codes

Covered Models:

KA4T, KB4T, KB8T

Covered Engines Codes:

4D5 SOHC, 4D56, 4M41

Covered Transmission Codes:

R5M21, R5MB1, V5MB1, R4AW4, V5A5A

👋 Introduction

Market Position

Vehicle Segment:

Mid-size pickup truck / Utility vehicle.

Target Audience:

Commercial users, off-road enthusiasts, fleet operators, and DIY mechanics.

Competitive Analysis

Key Competitors:

Toyota Hilux, Ford Ranger, Nissan Navara, Isuzu D-Max, Chevrolet Colorado.

Key Features

Value Proposition:

Known for its robustness, durability, and capable 4x4 systems, often offering a strong value proposition in its segment.

Manual Value:

Essential for owners and technicians to maintain, diagnose, and repair these vehicles effectively, covering a wide range of models and powertrains.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

Page Count

Estimated Page Count:

Extensive (typical for comprehensive workshop manuals, often 1000+ pages)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, lubrication, cooling, fuel injection (diesel), emission control, turbocharging (where applicable), engine management system (ECU).

Transmission Systems:

Manual transmission (R5M21, R5MB1, V5MB1), Automatic transmission (R4AW4, V5A5A) diagnostics, repair, overhaul, fluid specifications, torque converter.

Drivetrain Systems:

Front and rear axles, differential, driveshafts, propeller shaft, four-wheel drive system operation and repair.

Suspension Steering:

Front and rear suspension components (coil springs, leaf springs, shock absorbers, control arms), steering gear, power steering system, alignment specifications.

Brake Systems:

Front and rear brake systems (disc/drum), hydraulic circuits, ABS (Anti-lock Braking System) if equipped, parking brake.

Electrical Systems:

Battery, charging system (alternator), starting system, ignition system (if applicable to diesel variants), lighting, instrument panel, power windows, central locking, wiring diagrams.

HVAC Systems:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling.

Body Exterior Interior:

Body panel repair, doors, hood, tailgate, interior trim, seats, glass replacement.

Chassis Frame:

Frame inspection, repair, and maintenance.

Procedures Included

Maintenance Procedures:

Routine maintenance tasks, fluid changes, filter replacements, lubrication points, belt inspections and tensioning.

Diagnostic Procedures:

Troubleshooting guides, fault code interpretation (OBD-II if applicable), symptom-based diagnostics for various systems.

Repair Procedures:

Step-by-step repair instructions for all major mechanical and electrical components, including disassembly, assembly, and reassembly.

Overhaul Rebuild:

Detailed procedures for complete engine and transmission overhauls, including component specifications and tolerances.

Replacement Procedures:

Instructions for replacing wear items and major components such as alternators, starter motors, brake pads, clutch assemblies, and more.

Calibration Adjustment:

Procedures for adjusting clutch, brakes, and other systems as needed.

Technical Depth

Depth Of Coverage:

Comprehensive (covers everything from basic maintenance to full engine and transmission rebuilds).

Wiring Diagrams:

Includes detailed electrical system wiring diagrams for various configurations.

Torque Specifications:

Provides crucial torque specifications for all fasteners to ensure proper assembly and prevent damage.

Diagnostic Troubleshooting Charts:

Includes structured troubleshooting charts to systematically identify and resolve issues.

Component Drawings Illustrations:

Features exploded views and detailed illustrations of components for clarity during disassembly and reassembly.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format) - typically searchable and printable.

Print Quality

Digital Quality:

High resolution, clear text and diagrams for readability.

Binding Type

Digital Binding:

N/A (Digital)

Paper Type

Digital Paper Type:

N/A (Digital)

File Features

Searchability:

Text-searchable for quick access to specific information.

Printability:

Printable pages for convenient use in a workshop environment.

⚙️ Engine Specifications

Primary Engine

Engine Displacement 2500:

2.5 Liters (approx. 2500cc)

Engine Displacement 3200:

3.2 Liters (approx. 3200cc)

Engine 4D56:

2.5L 4-cylinder SOHC turbocharged diesel engine (various power outputs depending on market and specific model).

Engine 4M41:

3.2L 4-cylinder DOHC DI-D (Direct Injection Diesel) Common Rail turbocharged diesel engine (known for improved power and refinement over earlier engines).

Performance

Horsepower Range:

Typically ranging from 100 HP to over 170 HP depending on engine variant and market.

Torque Range:

Torque figures generally between 200 Nm and 400 Nm, maximizing towing and hauling capabilities.

Fuel System

Fuel Type:

Diesel

Injection System 4D56:

Indirect Injection (ID) or Direct Injection (DI) depending on sub-variant.

Injection System 4M41:

Common Rail Direct Injection (CRDI) with turbocharging.

🔧 Transmission

Standard

Standard Transmission Type:

Manual Transmission

Manual Gearboxes Covered:

R5M21 (5-speed manual), R5MB1 / V5MB1 (5-speed manual, often with different transfer case configurations).

Optional

Optional Transmission Type:

Automatic Transmission

Automatic Gearboxes Covered:

R4AW4 (4-speed automatic), V5A5A (5-speed automatic, typically found on higher specification models).

Features

Transfer Case Options:

Includes coverage for various 4WD (Four-Wheel Drive) systems and transfer cases, including part-time and full-time configurations.

Gear Ratios:

Manuals will contain specific gear ratios for each transmission and transfer case for accurate performance analysis and repair.

Fluid Specifications:

Details specific automatic transmission fluid (ATF) and manual gearbox oil types and capacities.

📐 Dimensions

Exterior

Body Styles:

Single Cab, Extended/Club Cab, Double Cab.

Wheelbase Range:

Varies by body style and configuration, typically between 3000mm and 3300mm.

Overall Length Range:

Varies by body style and cargo bed length, typically between 5000mm and 5400mm.

Ground Clearance:

Generally high for off-road capability, often exceeding 200mm.

Weights

Curb Weight Range:

Typically between 1700kg and 2100kg depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Often in the range of 2800kg to 3000kg.

Towing Capacity:

Varies significantly by market and specification, but typically capable of towing 2000kg to 3000kg.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Ratings vary by region and specific testing agency (e.g., ANCAP, Euro NCAP). Earlier models may have lower ratings than later ones.

Active Features

Anti-lock Braking System (ABS) often standard or optional.

Electronic Brake-force Distribution (EBD) commonly paired with ABS.

Traction Control:

Traction Control System (TCS) often available on higher trims or as an option.

Stability Control:

Electronic Stability Control (ESC) may be present on later models or specific markets.

Passive Features

Airbags:

Driver and front passenger airbags are common; side and curtain airbags may be available on higher trims.

Seatbelts:

Three-point seatbelts with pretensioners and load limiters for front occupants.

Child Anchors:

ISOFIX child seat mounting points.

💡 Technology Features

Infotainment

Audio System:

Varies by trim, could include AM/FM radio, CD player, MP3 playback, and basic speaker systems. Higher trims may offer touchscreens with navigation in later iterations.

Connectivity:

Auxiliary input jacks are common. Bluetooth connectivity may be present on mid-to-late models.

Driver Assistance

Cruise Control:

Available on some models, particularly higher trims.

Parking Sensors:

Rare on models from this era, but might be present on specific aftermarket additions or very high trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type.

Air Filter Replacement:

Recommended every 20,000-40,000 km or annually, more frequently in dusty conditions.

Fuel Filter Replacement:

Diesel fuel filters generally require replacement every 40,000-60,000 km.

Timing Belt Chain:

Check manual for specific timing belt replacement intervals if applicable (some variants may have chains). Typically 80,000-100,000 km for belts.

Fluid Specifications

Engine Oil Spec:

API CJ-4 or equivalent diesel engine oil, viscosity grades like 10W-30 or 15W-40 (consult manual for specific API and viscosity for 4D56/4M41).

Coolant Spec:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (or equivalent) recommended.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil for manual transmissions (specific viscosity to be confirmed in manual).

Transmission Fluid Automatic:

Specific ATF for the R4AW4 or V5A5A transmissions. Mitsubishi Genuine ATF J2 or equivalent is often specified.

Known Issues

Diesel Particulate Filter:

Potential for DPF clogging on models with diesel particulate filters, especially with short-distance driving cycles. Manual provides cleaning and regeneration procedures.

Glow Plugs:

Glow plug failure can lead to difficult cold starts; manual provides testing and replacement procedures.

Suspension Wear:

As with most pickup trucks, front suspension components (ball joints, bushings) can wear over time, particularly with heavy loads or off-road use.

Turbocharger Issues:

While generally robust, turbochargers can eventually fail due to age, oil starvation, or debris; the manual details diagnostic and replacement steps.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history dating back to 1917.

Model Evolution

Triton L200 Lineage:

The Triton (known as L200 in many markets) has been a cornerstone of Mitsubishi's commercial and lifestyle vehicle offerings for decades, evolving through multiple generations.

Relevant Generations:

Models KA4T, KB4T, KB8T typically fall within the fourth or early fifth generation of the Triton/L200 platform, produced roughly from the early 2000s to the mid-2010s, depending on specific market introductions.

Production

Manufacturing Locations:

Primarily manufactured in Thailand, with global distribution to numerous international markets.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The Triton/L200 range has received various 'Pickup of the Year' awards and accolades in different markets over its history, often praised for its value, capability, and reliability in its segment.

Ratings

Owner Satisfaction:

Generally good owner satisfaction, particularly in markets where it's a dominant player, often cited for its durability and lower cost of ownership compared to some competitors.