Mitsubishi L200 2005-2014 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Generation: Fourth Generation (KA/KB) Body Style: Pickup Truck Codes Platform Code: KA/KB Series 👋 Introduction Market Position Segment: Mid-size pickup truck, LCV (Light Commercial Vehicle) Reputation: Known for ruggedness, reliability, and capability, particularly in off-road and work applications Competitive Analysis Competitors: Toyota Hilux, Ford Ranger, Isuzu D-Max, Nissan Navara, Chevrolet Colorado Key Features Strengths: Robust chassis, reliable diesel engines, capable 4WD systems, practical utility Manual Value: Essential resource for owners and independent repair shops to maintain and repair the vehicle accurately and efficiently 📋 Manual Details Coverage Areas Model Years: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Regions: Global (specific to engine/transmission variants) Page Count Estimated Pages: Extensive (typically 1000+ pages for full workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management systems (ECU, sensors) Transmission: Manual transmission, Automatic transmission, Transfer case, Drivetrain components (driveshafts, differentials, axles) Chassis: Suspension (front and rear), Steering system, Braking system (hydraulic, ABS), Wheel alignment Electrical: Battery, Charging system, Starting system, Lighting system, Ignition system, Instrumentation, Power accessories, Body electrical systems, Powertrain control modules, Chassis control modules Body: Body panels, Doors, Hood, Tailgate, Interior trim, Seats, Glass, Bumpers, Chassis frame HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components and service Safety: Airbag system, Seatbelt mechanisms Procedures Included Maintenance: Routine servicing, Fluid changes, Filter replacements, Lubrication, Inspections Troubleshooting: Diagnostic procedures, Symptom-based troubleshooting, Fault code interpretation Repair Overhaul: Component removal, disassembly, inspection, repair, reassembly, and installation Diagnostics: Electrical system diagnostics, Engine diagnostics, Transmission diagnostics, ABS diagnostics Specifications: Torque specifications, Clearances, Measurements, Electrical schematics, Component identification Technical Depth Depth: Comprehensive (covers basic to advanced repairs, including full engine and transmission rebuilds) 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (allows for quick finding of information) Print Quality Quality: High-resolution scans, clear diagrams and illustrations Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Common: 4D56 (3.2L Diesel), 6G72 (3.0L V6 Petrol - less common in this generation for LCV markets) Engine Type: Inline 4-cylinder, Turbocharged Direct Injection Diesel (4D56) Displacement: 3.2 Liters (3200 cc) Bore X Stroke: 98.0 mm x 107.0 mm (typical for 4D56) Compression Ratio: 17.0:1 (typical for 4D56) Performance Horsepower 4D56: Approximately 165-178 PS (163-176 hp) depending on application and tuning Torque 4D56: Approximately 343-400 Nm (253-295 lb-ft) depending on application and tuning Fuel System Fuel Type: Diesel Injection System: Common Rail Direct Injection (CRDi) Turbocharger: Variable Geometry Turbocharger (VGT) standard on later models Emission Control: Euro 4 / Euro 5 compliant (varies by market and year) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission (with INVECS-II) Features Drivetrain: Part-time 4WD system (Super Select 4WD on some variants), Rear-wheel drive Transfer Case: Electronically controlled or manually operated transfer case 📐 Dimensions Exterior Length: Varies by body style (e.g., Single Cab, Double Cab), typically 5000-5300 mm Width: Varies by body style, typically 1750-1800 mm Height: Varies by body style, typically 1775-1800 mm Wheelbase: Varies by body style, typically 3000 mm Weights Curb Weight: Varies significantly by configuration, typically 1800-2100 kg Gross Vehicle Weight Rating Gvw: Typically around 2800-3000 kg Payload Capacity: Approximately 1000-1200 kg 🛡️ Safety Features Ratings Ancap Rating: Varies by market and specific tests, typically 4-star for models equipped with more safety features Active Features ABS: Anti-lock Braking System (standard on most models) Ebs: Electronic Brakeforce Distribution (EBD) Brake Assist: Brake Assist (BA) on some models Traction Control: Traction Control System (TCS) on some higher-spec models Passive Features Airbags: Driver and front passenger airbags (standard), side airbags and curtain airbags on higher trims Seatbelts: Pre-tensioner seatbelts, load limiters 💡 Technology Features Infotainment Head Unit: Factory fitted radio/CD player, some models with optional MP3 playback or aftermarket upgrades Speakers: Typically 2 or 4 speakers, higher trims may have more Driver Assistance Features: Limited by modern standards, focus on ABS, EBD, and optional TCS. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist typically found in this generation. Connectivity Features: Basic connectivity through AUX input or aftermarket Bluetooth adapters. 🔧 Maintenance Service Intervals Oil Change Diesel: Every 10,000 km or 6 months, whichever comes first Air Filter Diesel: Every 20,000 km or 12 months Fuel Filter Diesel: Every 40,000 km or 24 months Transmission Fluid Manual: Every 80,000 km or 48 months Transmission Fluid Automatic: Every 60,000 km or 36 months Fluid Specifications Engine Oil Diesel: API CI-4 or CJ-4, SAE 15W-40 or 5W-30 (synthetic recommended for colder climates) Engine Oil Capacity: Approximately 7.0-7.5 liters Coolant: Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with phosphate inhibitors), typically 50/50 mix Brake...
Comprehensive (covers basic to advanced repairs, including full engine and transmission rebuilds)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (allows for quick finding of information)
Print Quality
Quality:
High-resolution scans, clear diagrams and illustrations
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4D56 (3.2L Diesel), 6G72 (3.0L V6 Petrol - less common in this generation for LCV markets)
Engine Type:
Inline 4-cylinder, Turbocharged Direct Injection Diesel (4D56)
Displacement:
3.2 Liters (3200 cc)
Bore X Stroke:
98.0 mm x 107.0 mm (typical for 4D56)
Compression Ratio:
17.0:1 (typical for 4D56)
Performance
Horsepower 4D56:
Approximately 165-178 PS (163-176 hp) depending on application and tuning
Torque 4D56:
Approximately 343-400 Nm (253-295 lb-ft) depending on application and tuning
Fuel System
Fuel Type:
Diesel
Injection System:
Common Rail Direct Injection (CRDi)
Turbocharger:
Variable Geometry Turbocharger (VGT) standard on later models
Emission Control:
Euro 4 / Euro 5 compliant (varies by market and year)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission (with INVECS-II)
Features
Drivetrain:
Part-time 4WD system (Super Select 4WD on some variants), Rear-wheel drive
Transfer Case:
Electronically controlled or manually operated transfer case
📐 Dimensions
Exterior
Length:
Varies by body style (e.g., Single Cab, Double Cab), typically 5000-5300 mm
Width:
Varies by body style, typically 1750-1800 mm
Height:
Varies by body style, typically 1775-1800 mm
Wheelbase:
Varies by body style, typically 3000 mm
Weights
Curb Weight:
Varies significantly by configuration, typically 1800-2100 kg
Gross Vehicle Weight Rating Gvw:
Typically around 2800-3000 kg
Payload Capacity:
Approximately 1000-1200 kg
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by market and specific tests, typically 4-star for models equipped with more safety features
Active Features
ABS:
Anti-lock Braking System (standard on most models)
Ebs:
Electronic Brakeforce Distribution (EBD)
Brake Assist:
Brake Assist (BA) on some models
Traction Control:
Traction Control System (TCS) on some higher-spec models
Passive Features
Airbags:
Driver and front passenger airbags (standard), side airbags and curtain airbags on higher trims
Seatbelts:
Pre-tensioner seatbelts, load limiters
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radio/CD player, some models with optional MP3 playback or aftermarket upgrades
Speakers:
Typically 2 or 4 speakers, higher trims may have more
Driver Assistance
Features:
Limited by modern standards, focus on ABS, EBD, and optional TCS. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist typically found in this generation.
Connectivity
Features:
Basic connectivity through AUX input or aftermarket Bluetooth adapters.
🔧 Maintenance
Service Intervals
Oil Change Diesel:
Every 10,000 km or 6 months, whichever comes first
Air Filter Diesel:
Every 20,000 km or 12 months
Fuel Filter Diesel:
Every 40,000 km or 24 months
Transmission Fluid Manual:
Every 80,000 km or 48 months
Transmission Fluid Automatic:
Every 60,000 km or 36 months
Fluid Specifications
Engine Oil Diesel:
API CI-4 or CJ-4, SAE 15W-40 or 5W-30 (synthetic recommended for colder climates)
Engine Oil Capacity:
Approximately 7.0-7.5 liters
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with phosphate inhibitors), typically 50/50 mix
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Dexron II or III ATF (Automatic Transmission Fluid)
Known Issues
Common Problems:
Turbocharger failure (especially early models without VGT), injector issues on high-mileage diesel engines, DPF regeneration issues (if equipped), potential for suspension wear in heavy-duty use, EGR valve clogging
Maintenance Recommendations:
Regularly check and clean intercooler and radiator fins, ensure proper fuel quality, monitor for exhaust smoke
📚 Vehicle History
Brand Heritage
Brand:
Mitsubishi Motors Corporation
Heritage Focus:
Long history of producing robust and capable 4x4 vehicles and commercial vehicles
Model Evolution
Previous Generation:
Third Generation L200 (K70/K90 Series)
Design Philosophy:
Continuation of the 'Sport Utility Truck' concept, balancing utility with passenger comfort and off-road capability
Production
Production Years:
2005-2015 (for the fourth generation)
Manufacturing Locations:
Thailand (primary global production), Japan, Brazil, Philippines, Egypt
🏆 Awards & Recognition
Recognitions
Award Type:
Industry awards for utility, off-road capability, and value for money in various markets.
Target Market Awards:
Frequently awarded 'Pickup of the Year' or 'Best LCV' in numerous automotive publications and by specific user groups, particularly in Australia, the UK, and South Africa.
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