Mitsubishi L200 Triton 1996-2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Triton Generation: K60/K70 Series Body Style: Pickup Truck Production Years Covered: 1996-2004 Codes Chassis Codes: K62T, K64T, K66T, K72T, K74T, K75T, K76T, K77T 👋 Introduction Market Position Segment: Compact/Mid-size Pickup Truck (often referred to as a Sport Utility Truck or SUT) Competitive Analysis Competitors: Toyota Hilux, Nissan D22/D23 Navara, Ford Ranger, Isuzu D-Max Key Features Vehicle Appeal: Known for its ruggedness, off-road capability, and versatility as both a workhorse and a personal vehicle, often with comfortable interiors and a good balance of performance. Manual Value Proposition Benefit: Provides an inexpensive way to keep the vehicle in proper working order, empowering owners and mechanics with comprehensive technical data. 📋 Manual Details Coverage Areas Vehicle Systems: Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Suspension System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Steering System, Brake System, Body Interior and Exterior, Body Electrical System, Restraint System Page Count Estimated Pages: Extensive (specific page count not provided, but described as 'complete' and covering 'every detail') Manual Type Type: Workshop Service Repair Manual / Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed mechanical and electrical systems, including diagnostics, repair, and specifications for various engine variants of the period. Drivetrain: Comprehensive coverage of clutch system, manual transaxle, automatic transaxle, driveshaft, and axle repairs and maintenance. Chassis: In-depth information on suspension, steering, and brake systems, including troubleshooting and component replacement. Body And Electrical: Covers interior and exterior bodywork, as well as the complex body electrical system, including lighting, accessories, and the restraint system. Procedures Included Maintenance: Routine maintenance procedures, fluid changes, filter replacements, lubrication schedules. Repair: Step-by-step repair instructions for all major vehicle components, from engine teardown to body panel replacement. Diagnostics: Troubleshooting guides, diagnostic procedures for common issues, and wiring schematics for electrical system diagnosis. Technical Depth Depth: Suitable for both DIY enthusiasts and experienced professional mechanics, offering detailed illustrations, diagrams, and specifications for in-depth repairs and rebuilding. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Fully Printable Binding Type Binding: Digital (PDF) - Printable Paper Type Paper Type: N/A (Digital) Features Zoom Capability: Yes (Zoom IN/OUT) Searchability: Implied by PDF format, allowing for text search. Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Options Common: 4G63 2.0L I4 (Petrol), 4G64 2.4L I4 (Petrol), 4D56 2.5L I4 Diesel, 4M40 2.8L I4 Diesel (Turbocharged available) Performance Horsepower Range: Varies by engine, typically ranging from 90 hp for naturally aspirated diesels to 130+ hp for turbocharged variants and petrol engines. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) for petrol engines, Direct Injection or Indirect Injection for diesel engines, some with turbocharging. Cooling System Type: Liquid-cooled Ignition System Type: Electronic Ignition (Petrol) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission Features Drivetrain Options: Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations, often with manual or automatic locking hubs for 4WD models. Fluid Type Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (specifics depend on application, consult manual) Automatic Transmission Fluid: Dexron III or equivalent (specifics depend on application, consult manual) 📐 Dimensions Exterior Typical Length: Approx. 4.6 - 4.8 meters (varies by cab type and bed length) Typical Width: Approx. 1.7 - 1.8 meters Typical Height: Approx. 1.6 - 1.7 meters Weights Curb Weight: Varies by configuration, typically 1600-1900 kg Towing Capacity: Often rated up to 2000 kg or more, depending on engine and configuration (always check local regulations and vehicle load plates). 🛡️ Safety Features Ratings Crash Test Data: Data varies by region and testing body (e.g., NCAP). Generally, older models may have limited modern safety features compared to current vehicles. Active Features Braking System: Front ventilated disc brakes, rear drum brakes. Some higher trims or later models may feature ABS. Passive Features Airbags: Driver and passenger airbags generally available on most models, especially in later years or higher trim levels. Seatbelts: Pre-tensioning seatbelts for front occupants. 💡 Technology Features Infotainment Audio System: Factory-installed radios with AM/FM and cassette or CD players were common. Speaker configurations varied by trim level. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional or standard feature on higher trims or later models. Connectivity Connectivity Features: Limited to basic audio connectivity; no integrated Bluetooth or USB ports from the factory on most models of this era. 🔧 Maintenance Service Intervals Oil Change: Typically every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type. Consult the manual for specific recommendations. Timing Belt Replacement: For petrol engines with timing belts (e.g., 4G63, 4G64), replacement is typically recommended every 80,000 - 100,000 km or 5-7 years. Diesel engines may...
Compact/Mid-size Pickup Truck (often referred to as a Sport Utility Truck or SUT)
Competitive Analysis
Competitors:
Toyota Hilux, Nissan D22/D23 Navara, Ford Ranger, Isuzu D-Max
Key Features
Vehicle Appeal:
Known for its ruggedness, off-road capability, and versatility as both a workhorse and a personal vehicle, often with comfortable interiors and a good balance of performance.
Manual Value Proposition
Benefit:
Provides an inexpensive way to keep the vehicle in proper working order, empowering owners and mechanics with comprehensive technical data.
📋 Manual Details
Coverage Areas
Vehicle Systems:
Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Suspension System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Steering System, Brake System, Body Interior and Exterior, Body Electrical System, Restraint System
Page Count
Estimated Pages:
Extensive (specific page count not provided, but described as 'complete' and covering 'every detail')
Manual Type
Type:
Workshop Service Repair Manual / Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed mechanical and electrical systems, including diagnostics, repair, and specifications for various engine variants of the period.
Drivetrain:
Comprehensive coverage of clutch system, manual transaxle, automatic transaxle, driveshaft, and axle repairs and maintenance.
Chassis:
In-depth information on suspension, steering, and brake systems, including troubleshooting and component replacement.
Body And Electrical:
Covers interior and exterior bodywork, as well as the complex body electrical system, including lighting, accessories, and the restraint system.
Step-by-step repair instructions for all major vehicle components, from engine teardown to body panel replacement.
Diagnostics:
Troubleshooting guides, diagnostic procedures for common issues, and wiring schematics for electrical system diagnosis.
Technical Depth
Depth:
Suitable for both DIY enthusiasts and experienced professional mechanics, offering detailed illustrations, diagrams, and specifications for in-depth repairs and rebuilding.
Varies by engine, typically ranging from 90 hp for naturally aspirated diesels to 130+ hp for turbocharged variants and petrol engines.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) for petrol engines, Direct Injection or Indirect Injection for diesel engines, some with turbocharging.
Cooling System
Type:
Liquid-cooled
Ignition System
Type:
Electronic Ignition (Petrol)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
Available in 2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive) configurations, often with manual or automatic locking hubs for 4WD models.
Fluid Type
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (specifics depend on application, consult manual)
Automatic Transmission Fluid:
Dexron III or equivalent (specifics depend on application, consult manual)
📐 Dimensions
Exterior
Typical Length:
Approx. 4.6 - 4.8 meters (varies by cab type and bed length)
Typical Width:
Approx. 1.7 - 1.8 meters
Typical Height:
Approx. 1.6 - 1.7 meters
Weights
Curb Weight:
Varies by configuration, typically 1600-1900 kg
Towing Capacity:
Often rated up to 2000 kg or more, depending on engine and configuration (always check local regulations and vehicle load plates).
🛡️ Safety Features
Ratings
Crash Test Data:
Data varies by region and testing body (e.g., NCAP). Generally, older models may have limited modern safety features compared to current vehicles.
Active Features
Braking System:
Front ventilated disc brakes, rear drum brakes. Some higher trims or later models may feature ABS.
Passive Features
Airbags:
Driver and passenger airbags generally available on most models, especially in later years or higher trim levels.
Seatbelts:
Pre-tensioning seatbelts for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory-installed radios with AM/FM and cassette or CD players were common. Speaker configurations varied by trim level.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional or standard feature on higher trims or later models.
Connectivity
Connectivity Features:
Limited to basic audio connectivity; no integrated Bluetooth or USB ports from the factory on most models of this era.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type. Consult the manual for specific recommendations.
Timing Belt Replacement:
For petrol engines with timing belts (e.g., 4G63, 4G64), replacement is typically recommended every 80,000 - 100,000 km or 5-7 years. Diesel engines may use timing chains or belts.
Transmission Fluid Change:
Automatic transmissions: typically every 40,000 - 60,000 km. Manual transmissions: recommended at higher mileage or if experiencing issues.
Fluid Specifications
Engine Oil:
API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 for petrol. Diesel engines may require different specifications like API CF-4 or CG-4, SAE 15W-40.
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mixture with distilled water. Specific Mitsubishi coolant may be recommended.
Known Issues
Common Problems:
Potential issues can include wear in suspension components (bushings, ball joints), exhaust system rust, turbocharger issues on diesel models, and occasional electrical gremlins. Clutch wear is also a common maintenance item for manual transmissions.
Filters
Air Filter Part Example:
Part numbers vary by engine, e.g., MD620788 (for some 2.4L engines).
Oil Filter Part Example:
Part numbers vary by engine, e.g., MD095903 (for some 4G6 engines).
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Legacy:
Mitsubishi has a long history of producing robust and reliable pickup trucks, with the L200/Triton lineage tracing back to the early 1960s.
Model Evolution
Generation Context:
The K60/K70 series (1996-2004) represented a significant update from its predecessor, featuring a more aerodynamic design, improved interior comfort, and a wider range of engine options. It was built on a ladder frame chassis for durability.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Thailand, with assembly plants in other countries for specific markets.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific major awards for this exact generation aren't widely documented, the L200/Triton line has consistently been recognized for its durability, off-road prowess, and value in various global markets.
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