1997-2002 Mitsubishi L200 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Generation: Third Generation (K60/K70 Series) Production Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck / Utility Vehicle Key Attributes: Ruggedness, off-road capability, utility, reliability, often available with 4WD, practical for work and recreation. Competitive Analysis Primary Competitors: Toyota Hilux, Nissan D22 (Frontier/Navara), Ford Ranger, Isuzu D-Max (early models) Key Features Manual Value Proposition: Empowers DIY enthusiasts to perform maintenance and repairs, saving money and understanding their vehicle's mechanics. Provides detailed, factory-level information. 📋 Manual Details Coverage Areas Markets Covered: Global (Specific to L200 variants of this period, often referred to as Triton in many markets) Vehicle Variants: Covers various body styles (single cab, club cab, double cab) and drivetrain configurations (2WD, 4WD). Page Count Estimated Page Count: Extensive (typically over 1000 pages for a comprehensive factory service manual of this era) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Engine Lubrication, Fuel System (Gasoline & Diesel), Engine Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine and Emission Control Systems, Clutch System, Manual Transmission, Automatic Transmission, Transfer Case (4WD models), Propeller Shaft, Front Axle, Rear Axle Chassis And Body: Wheel and Tyre specifications, Power Plant Mounts, Suspension System (Front & Rear), Service Brakes (Hydraulic), Parking Brakes, Steering System, Body Construction, Exterior Components, Interior Components, SRS (Supplemental Restraint System) / Airbags, Chassis Electrical System Body Electrical: Lighting (headlights, taillights, interior), instrumentation, power windows/locks (if equipped), horn, wipers, washers, charging system, starting system. Procedures Included Maintenance And Inspection: Scheduled maintenance intervals, fluid level checks and changes, filter replacements, component inspections Diagnostics And Troubleshooting: Symptom-based diagnostics, fault code interpretation (OBD-I/OBD-II where applicable), troubleshooting flowcharts Repair And Overhaul: Step-by-step repair procedures for all major components, including engine disassembly/assembly, transmission overhauls, brake system repairs, suspension component replacement, body panel repair Electrical Systems: Wiring diagrams, component location, diagnostic procedures for lighting, starting, charging, ignition, and accessory systems Engine Performance Tuning: While not a tuning guide, it would provide specifications for engine timing, fuel pressure, and emissions control systems necessary for proper performance tuning. Body Repair: Procedures for body panel removal/installation, glass replacement, interior trim removal/installation, basic rust repair guidelines. Technical Depth Depth Of Information: Comprehensive; covers basic maintenance to complete vehicle overhauls, including detailed torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format File Format: PDF Compatibility Operating Systems: Compatible with all versions of Windows & Mac OS Requirements Software Requirement: Adobe PDF Reader (free download) File Quality Searchability: Likely contains searchable text, enabling quick navigation to specific topics. Printability: Printable, allowing users to create physical copies of specific sections or the entire manual. Diagram Quality: Factory service manuals typically feature high-quality, detailed diagrams and illustrations that are essential for repair procedures. ⚙️ Engine Specifications Primary Engine Options Gasoline Engine: 4G63 2.0L SOHC (Distributor ignition, MPI fuel injection common in early models); 4G64 2.4L SOHC (MPI) Diesel Engine: 4D56 2.5L SOHC Turbo Diesel (Common, various power outputs depending on market and tune); 4M40 2.8L SOHC Turbo Diesel (Less common in this specific generation for L200 branding, but used in Pajero/Montero Sport of the era) Performance Data Typical Horsepower Range: Gasoline: 110-135 HP; Diesel: 95-135 HP (Turbo models) Typical Torque Range: Gasoline: 125-145 lb-ft; Diesel: 150-200 lb-ft (Turbo models) Fuel System Gasoline Fuel Delivery: Multi-Point Fuel Injection (MPI) Diesel Fuel Delivery: Indirect Injection (IDI) or Direct Injection (DI) with Turbocharging, common rail injection not typical for this generation. Engine Management Ignition System: Distributor type with electronic control (gasoline); Glow plug system for cold starting (diesel) Emission Controls: Catalytic converter (gasoline), EGR system (diesel), crankcase ventilation. Manual covers diagnostic procedures for these systems. 🔧 Transmission Standard Transmission Manual Transmission Type: 5-Speed Manual (e.g., KM145, W5MG1) Optional Transmission Automatic Transmission Type: 4-Speed Automatic (e.g., V4A51) Transfer Case 4Wd System: Part-time 4WD with manual or electronic engagement, often featuring a transfer case with high and low range (e.g., Super Select 4WD variations on some models). Transmission Fluid Automatic Transmission Fluid Spec: Diamond SP-III (or equivalent ATF) Manual Transmission Fluid Spec: API GL-3 or GL-4 SAE 75W-90 Gear Oil (Check specific manual for exact viscosity and specification) 📐 Dimensions Exterior Body Styles: Single Cab, Extended Cab (Club Cab), Double Cab; various bed lengths (e.g., Standard Bed, Long Bed) Weights Curb Weight Range: Approximately 3,400 - 4,200 lbs (1,540 - 1,900 kg), depending on configuration and drivetrain. Towing Capacity Range: Varies significantly by market and configuration, typically up to 5,000-6,000 lbs (2,268-2,721 kg). 🛡️ Safety Features Passive Features Airbags: Driver's airbag typically standard on most models; Passenger airbag may be optional or standard depending on market and trim level. Seatbelts: 3-point seatbelts with pre-tensioners for front occupants. Active Features ABS: Anti-lock Braking System (ABS) often available as...
Ruggedness, off-road capability, utility, reliability, often available with 4WD, practical for work and recreation.
Competitive Analysis
Primary Competitors:
Toyota Hilux, Nissan D22 (Frontier/Navara), Ford Ranger, Isuzu D-Max (early models)
Key Features
Manual Value Proposition:
Empowers DIY enthusiasts to perform maintenance and repairs, saving money and understanding their vehicle's mechanics. Provides detailed, factory-level information.
📋 Manual Details
Coverage Areas
Markets Covered:
Global (Specific to L200 variants of this period, often referred to as Triton in many markets)
Vehicle Variants:
Covers various body styles (single cab, club cab, double cab) and drivetrain configurations (2WD, 4WD).
Page Count
Estimated Page Count:
Extensive (typically over 1000 pages for a comprehensive factory service manual of this era)
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Engine Lubrication, Fuel System (Gasoline & Diesel), Engine Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine and Emission Control Systems, Clutch System, Manual Transmission, Automatic Transmission, Transfer Case (4WD models), Propeller Shaft, Front Axle, Rear Axle
Chassis And Body:
Wheel and Tyre specifications, Power Plant Mounts, Suspension System (Front & Rear), Service Brakes (Hydraulic), Parking Brakes, Steering System, Body Construction, Exterior Components, Interior Components, SRS (Supplemental Restraint System) / Airbags, Chassis Electrical System
Symptom-based diagnostics, fault code interpretation (OBD-I/OBD-II where applicable), troubleshooting flowcharts
Repair And Overhaul:
Step-by-step repair procedures for all major components, including engine disassembly/assembly, transmission overhauls, brake system repairs, suspension component replacement, body panel repair
Electrical Systems:
Wiring diagrams, component location, diagnostic procedures for lighting, starting, charging, ignition, and accessory systems
Engine Performance Tuning:
While not a tuning guide, it would provide specifications for engine timing, fuel pressure, and emissions control systems necessary for proper performance tuning.
Body Repair:
Procedures for body panel removal/installation, glass replacement, interior trim removal/installation, basic rust repair guidelines.
Technical Depth
Depth Of Information:
Comprehensive; covers basic maintenance to complete vehicle overhauls, including detailed torque specifications, clearances, and diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Compatibility
Operating Systems:
Compatible with all versions of Windows & Mac OS
Requirements
Software Requirement:
Adobe PDF Reader (free download)
File Quality
Searchability:
Likely contains searchable text, enabling quick navigation to specific topics.
Printability:
Printable, allowing users to create physical copies of specific sections or the entire manual.
Diagram Quality:
Factory service manuals typically feature high-quality, detailed diagrams and illustrations that are essential for repair procedures.
⚙️ Engine Specifications
Primary Engine Options
Gasoline Engine:
4G63 2.0L SOHC (Distributor ignition, MPI fuel injection common in early models); 4G64 2.4L SOHC (MPI)
Diesel Engine:
4D56 2.5L SOHC Turbo Diesel (Common, various power outputs depending on market and tune); 4M40 2.8L SOHC Turbo Diesel (Less common in this specific generation for L200 branding, but used in Pajero/Montero Sport of the era)
Performance Data
Typical Horsepower Range:
Gasoline: 110-135 HP; Diesel: 95-135 HP (Turbo models)
Indirect Injection (IDI) or Direct Injection (DI) with Turbocharging, common rail injection not typical for this generation.
Engine Management
Ignition System:
Distributor type with electronic control (gasoline); Glow plug system for cold starting (diesel)
Emission Controls:
Catalytic converter (gasoline), EGR system (diesel), crankcase ventilation. Manual covers diagnostic procedures for these systems.
🔧 Transmission
Standard Transmission
Manual Transmission Type:
5-Speed Manual (e.g., KM145, W5MG1)
Optional Transmission
Automatic Transmission Type:
4-Speed Automatic (e.g., V4A51)
Transfer Case
4Wd System:
Part-time 4WD with manual or electronic engagement, often featuring a transfer case with high and low range (e.g., Super Select 4WD variations on some models).
Transmission Fluid
Automatic Transmission Fluid Spec:
Diamond SP-III (or equivalent ATF)
Manual Transmission Fluid Spec:
API GL-3 or GL-4 SAE 75W-90 Gear Oil (Check specific manual for exact viscosity and specification)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab; various bed lengths (e.g., Standard Bed, Long Bed)
Weights
Curb Weight Range:
Approximately 3,400 - 4,200 lbs (1,540 - 1,900 kg), depending on configuration and drivetrain.
Towing Capacity Range:
Varies significantly by market and configuration, typically up to 5,000-6,000 lbs (2,268-2,721 kg).
🛡️ Safety Features
Passive Features
Airbags:
Driver's airbag typically standard on most models; Passenger airbag may be optional or standard depending on market and trim level.
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants.
Active Features
ABS:
Anti-lock Braking System (ABS) often available as an option or standard on higher trims, especially in later years.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player and optional CD player. Speaker configurations varied by trim. Auxiliary input unlikely unless modified.
Driver Assistance
Cruise Control:
Available on higher trim levels and certain engine variants.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions and oil type. Consult manual for exact recommendation.
Timing Belt Replacement:
For gasoline engines (e.g., 4G63/4G64), timing belt replacement is crucial, typically around 60,000-90,000 miles (100,000-150,000 km). Diesel engines often use timing chains, but some early diesel models might have belts. ALWAYS verify with the manual.
Fluid Specifications
Engine Oil Spec Gasoline:
API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 is common. Consult manual for specific viscosity based on climate.
Engine Oil Spec Diesel:
API CF-4 or CG-4 or higher, SAE 10W-30 or 15W-40 diesel engine oil. Consult manual for specific viscosity.
Coolant Spec:
Ethylene glycol-based antifreeze, typically a green or orange coolant. Capacity around 7-8 Liters. Ensure proper mix of antifreeze and distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 hydraulic brake fluid. Ensure adherence to the specified type.
Power Steering Fluid Spec:
Typically ATF Dexron II/III or a specific power steering fluid. Consult manual for exact type.
Known Issues
Common Wear Items:
Clutch wear, suspension bushings and ball joints, exhaust system corrosion, glow plug issues (diesel), potential turbocharger issues on high-mileage diesel engines, front CV joints (4WD models).
Electrical Gremlins:
Corroded grounds, aging wiring harnesses, and failing relays can cause intermittent electrical issues, common in older vehicles.
Diesel Specific:
Cylinder head gasket issues on some 4D56 engines under heavy load or overheating, fuel injector pump seals, intake manifold clogging with soot on turbocharged diesels.
Cooling System:
Radiator leaks, thermostat failures, water pump issues can occur with age and mileage. Overheating can lead to severe engine damage.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors has a long history of producing reliable and rugged vehicles, particularly trucks and SUVs, with a strong presence in off-road and utility segments.
Model Evolution
L200 Legacy:
The L200 (also known as Triton, Strada, Mighty Max in other markets) has been a consistent seller for Mitsubishi, evolving through several generations to meet diverse global market demands for pickup trucks.
Generation Nickname:
Often referred to as the 'shape' of the L200 that preceded the fully rounded designs, retaining a more utilitarian and angular appearance compared to its predecessor.
Design Philosophy:
The K60/K70 series marked a transition in design language for Mitsubishi trucks, offering improved aerodynamics and creature comforts while maintaining robust construction and capability.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Thailand.
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