Mitsubushi L200 STRADA TRITON Service Repair Manual 1997-2002

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200/Strada/Triton Generation: Third Generation Generation Codes: K60/K70 Series Production Years Covered: 1997-2002 👋 Introduction Market Position Vehicle Segment: Compact Pickup Truck / Utility Vehicle Target Audience: Tradespeople, fleet operators, off-road enthusiasts, general utility vehicle owners Competitive Analysis Key Competitors: Toyota Hilux, Nissan Navara/Frontier, Ford Ranger, Chevrolet Colorado/S-10, Isuzu D-Max Key Features Vehicle Strengths: Robust construction, reliable powertrains, capable off-road (4WD models), versatility as a workhorse Manual Value Proposition: Empowers owners and technicians with factory-level repair information, reducing reliance on dealerships and unauthorized repair shops. 📋 Manual Details Coverage Areas Market Segments: Global (North America, Europe, Asia, Australia, etc.) Body Styles: Single Cab, Double Cab, Club Cab, Chassis Cab, Panel Van (where applicable) Drivetrain: 2WD (RWD), 4WD (4x4) Page Count Estimated Pages: High Volume (likely 1000+ pages, typical for comprehensive service manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Digital Format: PDF (Searchable, Printable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cylinder head, pistons, crankshaft, camshaft, timing systems (belt/chain), oil pump, lubrication system Engine Management: Fuel injection systems (MPI, DI), electronic control unit (ECU), sensors, actuators, emission control systems Cooling System: Radiator, thermostat, water pump, cooling fan, hoses, coolant specifications Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulation Exhaust System: Exhaust manifold, catalytic converter, mufflers, exhaust pipes, emissions Transmission Manual: Clutch operation, master/slave cylinders, transmission assembly/disassembly, gear ratios, shift linkage, lubricant specifications Transmission Automatic: Torque converter, valve body, planetary gears, transmission control unit (TCU), fluid specifications Transfer Case 4Wd: Operation, maintenance, lubrication, repair (for 4WD models) Drivetrain Axles: Front and rear differentials, CV joints, driveshafts, propeller shafts, U-joints, lubricant specifications Suspension Front: Independent suspension components (e.g., torsion bar, control arms, ball joints, shock absorbers), alignment specifications Suspension Rear: Leaf spring or coil spring suspension, shock absorbers, control arms, axle, alignment specifications Steering System: Steering column, steering gear (rack and pinion or recirculating ball), power steering pump, fluid specifications, tie rods, linkages Brake System: Front disc brakes, rear drum or disc brakes, hydraulic system, master cylinder, brake lines, calipers, wheel cylinders, parking brake, ABS (if equipped), fluid specifications Wheels Tires: Wheel specifications, bolt patterns, tire sizes, inflation pressures, rotation, balancing Body Exterior: Body panel removal/installation, doors, hood, tailgate, bumpers, trim, glass, rust repair, paint codes Body Interior: Dashboard, seats, upholstery, door panels, headliner, interior trim, carpeting Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, switches Instrument Panel: Gauges, warning lights, indicators, instrument cluster removal/installation HVAC System: Air conditioning (compressor, condenser, evaporator, refrigerant), heating system, ventilation, blower motor, controls Wiring Diagrams: Comprehensive wiring diagrams for all electrical circuits (engine, chassis, body, lighting, accessories) Fault Finding: Diagnostic trouble codes (DTCs), troubleshooting charts, symptom-based diagnostics, common failure points Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake checks Engine Overhaul: Complete engine rebuild procedures, including torque specifications, gasket replacement, component measurements Transmission Repair: Detailed steps for manual and automatic transmission disassembly, inspection, repair, and reassembly Brake System Repair: Brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding, rotor/drum servicing Suspension And Steering Repair: Ball joint replacement, tie rod end replacement, shock absorber installation, power steering pump replacement, wheel alignment procedures Electrical Component Replacement: Alternator, starter motor, battery, light bulbs, fuses, relays, sensors, switches Body Panel Replacement: Procedures for replacing fenders, doors, hoods, tailgates, and other exterior body panels Diagnostic Troubleshooting: Step-by-step guides for diagnosing and resolving common and complex mechanical and electrical faults HVAC Service: Refrigerant handling, compressor replacement, leak detection, heater core service Technical Depth Depth: Comprehensive (covers everything from basic maintenance to full engine and transmission rebuilds, including diagnostics) Diagnostic Tools: References to factory diagnostic tools and procedures, including OBD-II scan tool usage for applicable models/regions Technical Specifications: Detailed torque specifications, clearances, fluid capacities, chemical compositions, electrical resistance values, etc. Illustrations: High-quality photographs and detailed diagrams/schematics for all procedures and component identification 📊 Manual Specifications File Format Digital File Type: PDF Searchability: Text-searchable PDF (allows for quick keyword searches) Print Quality Printability: Printable (pages can be printed for hands-on workshop use) Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Options Engine Code Petrol 1: 4G63 (2.0L SOHC) Engine Code Petrol 2: 4G64 (2.4L SOHC/DOHC) Engine Code Diesel 1: 4D56 (2.5L SOHC Turbo Diesel) Engine Code Diesel 2: 4M40 (2.8L SOHC Turbo Diesel) Performance Petrol 2.4L Displacement Petrol 2.4: 2351 cc (2.4 Liters) Horsepower Petrol 2.4 Sohc: ~123-145 PS (approx. 121-143 hp) depending on market and tuning Torque Petrol 2.4 Sohc: ~190-215 Nm (approx. 140-159 lb-ft) depending on market and tuning Performance Diesel 2.5L Displacement Diesel 2.5: 2477 cc (2.5 Liters) Horsepower Diesel 2.5: ~99-103 PS (approx. 98-102 hp) depending on tuning Torque...

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Tags: 1997 1998 1999 2000 2001 2002 Cars L200 Mitsubishi STRADA TRITON Truck

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

L200/Strada/Triton

Generation:

Third Generation

Generation Codes:

K60/K70 Series

Production Years Covered:

1997-2002

👋 Introduction

Market Position

Vehicle Segment:

Compact Pickup Truck / Utility Vehicle

Target Audience:

Tradespeople, fleet operators, off-road enthusiasts, general utility vehicle owners

Competitive Analysis

Key Competitors:

Toyota Hilux, Nissan Navara/Frontier, Ford Ranger, Chevrolet Colorado/S-10, Isuzu D-Max

Key Features

Vehicle Strengths:

Robust construction, reliable powertrains, capable off-road (4WD models), versatility as a workhorse

Manual Value Proposition:

Empowers owners and technicians with factory-level repair information, reducing reliance on dealerships and unauthorized repair shops.

📋 Manual Details

Coverage Areas

Market Segments:

Global (North America, Europe, Asia, Australia, etc.)

Body Styles:

Single Cab, Double Cab, Club Cab, Chassis Cab, Panel Van (where applicable)

Drivetrain:

2WD (RWD), 4WD (4x4)

Page Count

Estimated Pages:

High Volume (likely 1000+ pages, typical for comprehensive service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF (Searchable, Printable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, pistons, crankshaft, camshaft, timing systems (belt/chain), oil pump, lubrication system

Engine Management:

Fuel injection systems (MPI, DI), electronic control unit (ECU), sensors, actuators, emission control systems

Cooling System:

Radiator, thermostat, water pump, cooling fan, hoses, coolant specifications

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulation

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, exhaust pipes, emissions

Transmission Manual:

Clutch operation, master/slave cylinders, transmission assembly/disassembly, gear ratios, shift linkage, lubricant specifications

Transmission Automatic:

Torque converter, valve body, planetary gears, transmission control unit (TCU), fluid specifications

Transfer Case 4Wd:

Operation, maintenance, lubrication, repair (for 4WD models)

Drivetrain Axles:

Front and rear differentials, CV joints, driveshafts, propeller shafts, U-joints, lubricant specifications

Suspension Front:

Independent suspension components (e.g., torsion bar, control arms, ball joints, shock absorbers), alignment specifications

Suspension Rear:

Leaf spring or coil spring suspension, shock absorbers, control arms, axle, alignment specifications

Steering System:

Steering column, steering gear (rack and pinion or recirculating ball), power steering pump, fluid specifications, tie rods, linkages

Brake System:

Front disc brakes, rear drum or disc brakes, hydraulic system, master cylinder, brake lines, calipers, wheel cylinders, parking brake, ABS (if equipped), fluid specifications

Wheels Tires:

Wheel specifications, bolt patterns, tire sizes, inflation pressures, rotation, balancing

Body Exterior:

Body panel removal/installation, doors, hood, tailgate, bumpers, trim, glass, rust repair, paint codes

Body Interior:

Dashboard, seats, upholstery, door panels, headliner, interior trim, carpeting

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, switches

Instrument Panel:

Gauges, warning lights, indicators, instrument cluster removal/installation

HVAC System:

Air conditioning (compressor, condenser, evaporator, refrigerant), heating system, ventilation, blower motor, controls

Wiring Diagrams:

Comprehensive wiring diagrams for all electrical circuits (engine, chassis, body, lighting, accessories)

Fault Finding:

Diagnostic trouble codes (DTCs), troubleshooting charts, symptom-based diagnostics, common failure points

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake checks

Engine Overhaul:

Complete engine rebuild procedures, including torque specifications, gasket replacement, component measurements

Transmission Repair:

Detailed steps for manual and automatic transmission disassembly, inspection, repair, and reassembly

Brake System Repair:

Brake pad/shoe replacement, caliper/wheel cylinder service, brake bleeding, rotor/drum servicing

Suspension And Steering Repair:

Ball joint replacement, tie rod end replacement, shock absorber installation, power steering pump replacement, wheel alignment procedures

Electrical Component Replacement:

Alternator, starter motor, battery, light bulbs, fuses, relays, sensors, switches

Body Panel Replacement:

Procedures for replacing fenders, doors, hoods, tailgates, and other exterior body panels

Diagnostic Troubleshooting:

Step-by-step guides for diagnosing and resolving common and complex mechanical and electrical faults

HVAC Service:

Refrigerant handling, compressor replacement, leak detection, heater core service

Technical Depth

Depth:

Comprehensive (covers everything from basic maintenance to full engine and transmission rebuilds, including diagnostics)

Diagnostic Tools:

References to factory diagnostic tools and procedures, including OBD-II scan tool usage for applicable models/regions

Technical Specifications:

Detailed torque specifications, clearances, fluid capacities, chemical compositions, electrical resistance values, etc.

Illustrations:

High-quality photographs and detailed diagrams/schematics for all procedures and component identification

📊 Manual Specifications

File Format

Digital File Type:

Searchability:

Text-searchable PDF (allows for quick keyword searches)

Print Quality

Printability:

Printable (pages can be printed for hands-on workshop use)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Options

Engine Code Petrol 1:

4G63 (2.0L SOHC)

Engine Code Petrol 2:

4G64 (2.4L SOHC/DOHC)

Engine Code Diesel 1:

4D56 (2.5L SOHC Turbo Diesel)

Engine Code Diesel 2:

4M40 (2.8L SOHC Turbo Diesel)

Performance Petrol 2.4L

Displacement Petrol 2.4:

2351 cc (2.4 Liters)

Horsepower Petrol 2.4 Sohc:

~123-145 PS (approx. 121-143 hp) depending on market and tuning

Torque Petrol 2.4 Sohc:

~190-215 Nm (approx. 140-159 lb-ft) depending on market and tuning

Performance Diesel 2.5L

Displacement Diesel 2.5:

2477 cc (2.5 Liters)

Horsepower Diesel 2.5:

~99-103 PS (approx. 98-102 hp) depending on tuning

Torque Diesel 2.5:

~200-230 Nm (approx. 148-170 lb-ft) depending on tuning

Performance Diesel 2.8L

Displacement Diesel 2.8:

2835 cc (2.8 Liters)

Horsepower Diesel 2.8:

~125-135 PS (approx. 123-133 hp) depending on tuning

Torque Diesel 2.8:

~240-270 Nm (approx. 177-199 lb-ft) depending on tuning

Fuel System

Fuel Injection Petrol:

Multi-Point Fuel Injection (MPI)

Fuel Type Petrol:

Unleaded Gasoline (Octane rating varies by market)

Fuel Type Diesel:

Diesel Fuel

Turbocharger:

Standard on diesel engines (Intercooled Turbo for some variants)

🔧 Transmission

Standard Transmission

Manual Options:

5-speed Manual Transmission

Optional Transmission

Automatic Options:

4-speed Automatic Transmission (4WD/2WD availability varies)

Features

Transfer Case Type:

Part-time 4WD with manual (or electronic push-button) engagement and low-range gearing (Super Select 4WD system or similar variations).

Clutch Type:

Dry single-plate clutch (for manual transmissions)

📐 Dimensions

Exterior Length

Length Typical:

Approx. 4.6m - 5.1m (depending on body style and bed length)

Exterior Width

Width Typical:

Approx. 1.7m - 1.8m

Exterior Height

Height Typical:

Approx. 1.6m - 1.7m

Wheelbase

Wheelbase Options:

Approx. 2.9m - 3.0m (Standard and Long Wheelbase variants)

Cargo Bed

Bed Length Options:

Multiple bed lengths available, typically ranging from ~1.5m to ~1.8m

Weights

Curb Weight Range:

Approx. 1600 kg - 2000 kg (depending on configuration)

Gross Vehicle Weight Rating Gvwr:

Varies by model, typically around 2500 kg - 2800 kg

🛡️ Safety Features

Ratings

Crash Test Data:

Limited publicly available data for this generation across all global markets; focus on structural integrity and occupant protection for its class.

Active Features

Available on some models/trims (Anti-lock Braking System)

Limited Slip Differential:

Available on some 4WD models

Passive Features

Airbags:

Driver and passenger airbags available on higher trims and later models within the range.

Seatbelts:

3-point seatbelts with pretensioners (driver/front passenger)

💡 Technology Features

Infotainment

Head Unit Options:

Basic AM/FM radio with CD player or cassette tape player. Higher trims might have upgraded stereo systems.

Driver Assistance

Traction Control:

Rarely found on this generation.

Hill Descent Control:

Not typically available.

Connectivity

Bluetooth:

Not available from factory.

Instrumentation

Gauge Cluster:

Analog gauges for speedometer, tachometer, fuel level, and engine temperature. Warning lights for various systems.

🔧 Maintenance

Service Intervals Oil Change

Petrol Engine Oil Filter:

Every 5,000-10,000 km (3,000-6,000 miles) or 6 months, whichever comes first (consult manual for specific recommendation).

Diesel Engine Oil Filter:

Every 5,000-10,000 km (3,000-6,000 miles) or 6 months, whichever comes first (consult manual for specific recommendation, especially with turbocharging).

Service Intervals Major Service

Timing Belt Replacement:

Typically 100,000 km (60,000 miles) or 5 years for petrol engines (check manual for specific engine and belt type). Diesel engines may use timing chains or belts with different intervals.

Fluid Specifications

Engine Oil Petrol:

API SG/SH or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity and API rating based on climate).

Engine Oil Diesel:

API CF-4/CG-4 or higher, SAE 15W-40 or 10W-40 (check manual for specific viscosity and API rating based on climate, especially for turbo diesel).

Coolant:

Ethylene glycol-based antifreeze (e.g., Mitsubishi Diaqueen Super Long Life Coolant or equivalent) mixed 50/50 with distilled water.

Transmission Fluid Manual:

API GL-4 SAE 75W-90 or 75W-85 gear oil (check manual for precise specification).

Transmission Fluid Automatic:

Dexron III or equivalent ATF (Automatic Transmission Fluid). Check manual for specific type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Always use fresh, sealed fluid.

Power Steering Fluid:

Use genuine Mitsubishi power steering fluid or Dexron II/III ATF. Consult manual.

Known Issues

Diesel Glow Plugs:

Glow plug failure can lead to difficult cold starts.

Turbocharger Diesel:

Turbo seals or wastegate issues can arise with age and mileage.

Suspension Wear:

Leaf springs can sag, and bushings can wear out, especially on heavily used vehicles.

Body Rust:

Common rust areas include wheel arches, sills, and chassis components, especially in corrosive climates.

Clutch Wear:

Clutch assembly wear is normal with mileage and usage, requiring replacement.

📚 Vehicle History

Brand Heritage

Mitsubishi Truck Legacy:

Mitsubishi has a long history of producing robust and reliable pickup trucks, dating back to the 1970s. The L200/Triton lineage is a key part of this.

Model Evolution

Third Generation Introduction:

Introduced in late 1996 for the 1997 model year, this generation marked a significant styling and engineering update over its predecessor, offering improved comfort and capability.

Key Design Changes:

Smoother, more aerodynamic styling compared to the previous generation. Improved interior ergonomics and comfort. Introduction of more powerful engine options.

Production

Manufacturing Locations:

Primarily produced in Japan and Thailand, with assembly in various other global locations.

🏆 Awards & Recognition

Recognitions

Vehicle Awards:

Specific awards vary by market and trim. Often recognized for value, durability, and off-road capability in its segment.