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Mitsubishi Triton L200 1997 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Triton L200 Model Designation: L200 Generation Code: K60/K70 Series Codes Chassis Codes: K60 (2WD), K70 (4WD) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size Pickup Truck Target Audience: Workhorse utility vehicle, lifestyle vehicle. Competitive Analysis Key Competitors Era: Toyota Hilux, Nissan Navara (D22), Ford Ranger (PJ/PK), Isuzu D-Max (first gen). Key Features Vehicle Strengths: Robust chassis, reliable powertrains, off-road capability, utilitarian design. Manual Advantage: Comprehensive diagnostic and repair information used by professional mechanics. Manual Benefit: Empowers owners and technicians with detailed knowledge for efficient repairs and maintenance. Accessibility: Instant download, no shipping, immediate access to critical information. 📋 Manual Details Coverage Areas Model Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Specific Regions Covered: Global (based on typical Mitsubishi Triton/L200 specifications for this era) Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Service Manual / Workshop Manual / Repair Manual Language Language: English Format Delivery Format: Digital Download (PDF) File Format: PDF Searchability: Likely text-searchable PDF (allows quick lookup of terms). Printability: Printable pages. 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, including disassembly, inspection, assembly, and torque specifications. Engine Lubrication System: Oil pump, oil filter, oil cooler, oil passages, pressure testing. Engine Cooling System: Radiator, thermostat, water pump, coolant hoses, fan clutch, pressure testing, flush procedures. Fuel System: Fuel pump, injectors, fuel filter, fuel lines, fuel pressure testing, EVAP system. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, leak detection. Automatic Transmission: Transmission overhaul, hydraulic control, torque converter, shift solenoids, fluid service, diagnostics. Manual Transmission: Transmission overhaul, clutch operation, gear selection, fluid service, diagnostics. Propeller Shaft: U-joints, slip yokes, balancing, removal and installation. Rear Axle: Differential overhaul, axle shafts, bearings, seals, fluid specifications, backlash adjustment. Front Axle: CV joints, hub bearings, seals, differential (for 4WD models), lubrication. Front Suspension: Shock absorbers, springs, control arms, ball joints, bushings, alignment procedures. Rear Suspension: Leaf springs, shock absorbers, bushings, U-bolts, alignment procedures. Wheels And Tires: Tire pressure, rotation, balancing, wheel alignment specifications. Brake System: Disc brakes, drum brakes, ABS system, hydraulic lines, master cylinder, caliper/wheel cylinder overhaul, bleeding procedures. Steering System: Power steering pump, steering rack/gearbox, tie rod ends, steering column, fluid specifications, alignment. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, wiring diagrams, fuses, relays, diagnostic connectors. HVAC: Air conditioning system, heater core, blower motor, refrigerant types, charge procedures, diagnostics. Body: Body panels, doors, windows, locks, mirrors, interior trim, bumpers, corrosion protection. Accelerator Control System: Throttle body, throttle cables/actuation, cruise control (if equipped). Clutch: Clutch disc, pressure plate, release bearing, master cylinder, slave cylinder, hydraulic lines, bleeding procedures. Procedures Included Maintenance: Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication points. Troubleshooting: Diagnostic charts, symptom-based problem solving, fault code interpretation (if applicable). Repair: Step-by-step repair procedures for all major vehicle systems. Diagnostics: Detailed diagnostic procedures, including electrical circuit testing and component testing. Installation: Procedures for installing replacement parts and accessories. Rebuilds: Comprehensive rebuild instructions for engines, transmissions, and axles. Technical Depth Depth Of Information: Professional Level (suitable for experienced mechanics and DIY enthusiasts). Diagrams And Illustrations: Extensive detailed diagrams, exploded views, and schematics. Torque Specifications: All critical torque specifications for fasteners throughout the vehicle. Clearances And Tolerances: Precise specifications for component clearances and wear tolerances. Wiring Diagrams: Comprehensive, system-specific electrical wiring schematics. 📊 Manual Specifications File Format Compatibility: Windows XP/Vista/Seven, macOS, Linux Print Quality Illustration Clarity: High-resolution, clear illustrations and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Codes Common: 4G63 (2.0L Petrol), 4G64 (2.4L Petrol), 4D56 (2.5L Diesel - naturally aspirated and turbo), 4M40 (2.8L Diesel - turbo intercooled). Performance Horsepower Range: Approx. 95 HP (NA Diesel) to 140 HP (Turbo Diesel/Petrol). Torque Range: Approx. 175 Nm (NA Diesel) to 250+ Nm (Turbo Diesel). Fuel System Fuel Injection Types: Carbureted (early petrol models), Electronic Fuel Injection (EFI) for petrol, Direct Injection (DI) or Indirect Injection (IDI) for diesel. Turbocharging: Common on 4D56 and 4M40 diesel variants, often with intercooler. Engine Mechanical Cylinder Configuration: Inline 4-Cylinder Valvetrain: SOHC or DOHC depending on engine. 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission Features Drivetrain Options: 2WD (RWD) and 4WD (4x4) with selectable or full-time 4WD options. Transfer Case: 2-speed transfer case with low-range gearing on many 4WD models. 📐 Dimensions Exterior Body Styles: Single Cab, Extended Cab (Club Cab), Double Cab. Bed Lengths: Various bed lengths depending on cab configuration and market. Weights Curb Weight Range: Approx. 1600 kg - 2000 kg (depending on configuration). Towing Capacity: Varies significantly by engine and drivetrain, typically 1500 kg - 2500 kg. 🛡️ Safety Features Ratings Crash Test Data: Limited official global ratings for this specific generation; focused on structural integrity...
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Mitsubishi Triton L200 1997 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Triton L200
Model Designation:
L200
Generation Code:
K60/K70 Series
Codes
Chassis Codes:
K60 (2WD), K70 (4WD)
👋 Introduction
Market Position
Vehicle Segment:
Compact/Mid-size Pickup Truck
Target Audience:
Workhorse utility vehicle, lifestyle vehicle.
Competitive Analysis
Key Competitors Era:
Toyota Hilux, Nissan Navara (D22), Ford Ranger (PJ/PK), Isuzu D-Max (first gen).
Key Features
Vehicle Strengths:
Robust chassis, reliable powertrains, off-road capability, utilitarian design.
Manual Advantage:
Comprehensive diagnostic and repair information used by professional mechanics.
Manual Benefit:
Empowers owners and technicians with detailed knowledge for efficient repairs and maintenance.
Accessibility:
Instant download, no shipping, immediate access to critical information.
📋 Manual Details
Coverage Areas
Model Years Covered:
1997, 1998, 1999, 2000, 2001, 2002
Specific Regions Covered:
Global (based on typical Mitsubishi Triton/L200 specifications for this era)
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive factory service manuals)
Manual Type
Manual Type:
Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Delivery Format:
Digital Download (PDF)
File Format:
PDF
Searchability:
Likely text-searchable PDF (allows quick lookup of terms).
Printability:
Printable pages.
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine overhaul, including disassembly, inspection, assembly, and torque specifications.
Engine Lubrication System:
Oil pump, oil filter, oil cooler, oil passages, pressure testing.
Engine Cooling System:
Radiator, thermostat, water pump, coolant hoses, fan clutch, pressure testing, flush procedures.
Fuel System:
Fuel pump, injectors, fuel filter, fuel lines, fuel pressure testing, EVAP system.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, leak detection.
Automatic Transmission:
Transmission overhaul, hydraulic control, torque converter, shift solenoids, fluid service, diagnostics.
Manual Transmission:
Transmission overhaul, clutch operation, gear selection, fluid service, diagnostics.
Propeller Shaft:
U-joints, slip yokes, balancing, removal and installation.
Rear Axle:
Differential overhaul, axle shafts, bearings, seals, fluid specifications, backlash adjustment.
Front Axle:
CV joints, hub bearings, seals, differential (for 4WD models), lubrication.
Front Suspension:
Shock absorbers, springs, control arms, ball joints, bushings, alignment procedures.
Rear Suspension:
Leaf springs, shock absorbers, bushings, U-bolts, alignment procedures.
Wheels And Tires:
Tire pressure, rotation, balancing, wheel alignment specifications.
Brake System:
Disc brakes, drum brakes, ABS system, hydraulic lines, master cylinder, caliper/wheel cylinder overhaul, bleeding procedures.
Steering System:
Power steering pump, steering rack/gearbox, tie rod ends, steering column, fluid specifications, alignment.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, wiring diagrams, fuses, relays, diagnostic connectors.
HVAC:
Air conditioning system, heater core, blower motor, refrigerant types, charge procedures, diagnostics.
Body:
Body panels, doors, windows, locks, mirrors, interior trim, bumpers, corrosion protection.
Accelerator Control System:
Throttle body, throttle cables/actuation, cruise control (if equipped).
Clutch:
Clutch disc, pressure plate, release bearing, master cylinder, slave cylinder, hydraulic lines, bleeding procedures.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication points.
Troubleshooting:
Diagnostic charts, symptom-based problem solving, fault code interpretation (if applicable).
Repair:
Step-by-step repair procedures for all major vehicle systems.
Diagnostics:
Detailed diagnostic procedures, including electrical circuit testing and component testing.
Installation:
Procedures for installing replacement parts and accessories.
Rebuilds:
Comprehensive rebuild instructions for engines, transmissions, and axles.
Technical Depth
Depth Of Information:
Professional Level (suitable for experienced mechanics and DIY enthusiasts).
Diagrams And Illustrations:
Extensive detailed diagrams, exploded views, and schematics.
Torque Specifications:
All critical torque specifications for fasteners throughout the vehicle.
Clearances And Tolerances:
Precise specifications for component clearances and wear tolerances.
Wiring Diagrams:
Comprehensive, system-specific electrical wiring schematics.
📊 Manual Specifications
File Format
Compatibility:
Windows XP/Vista/Seven, macOS, Linux
Print Quality
Illustration Clarity:
High-resolution, clear illustrations and diagrams.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Codes Common:
4G63 (2.0L Petrol), 4G64 (2.4L Petrol), 4D56 (2.5L Diesel - naturally aspirated and turbo), 4M40 (2.8L Diesel - turbo intercooled).
Performance
Horsepower Range:
Approx. 95 HP (NA Diesel) to 140 HP (Turbo Diesel/Petrol).
Torque Range:
Approx. 175 Nm (NA Diesel) to 250+ Nm (Turbo Diesel).
Fuel System
Fuel Injection Types:
Carbureted (early petrol models), Electronic Fuel Injection (EFI) for petrol, Direct Injection (DI) or Indirect Injection (IDI) for diesel.
Turbocharging:
Common on 4D56 and 4M40 diesel variants, often with intercooler.
Engine Mechanical
Cylinder Configuration:
Inline 4-Cylinder
Valvetrain:
SOHC or DOHC depending on engine.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
2WD (RWD) and 4WD (4x4) with selectable or full-time 4WD options.
Transfer Case:
2-speed transfer case with low-range gearing on many 4WD models.
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab.
Bed Lengths:
Various bed lengths depending on cab configuration and market.
Weights
Curb Weight Range:
Approx. 1600 kg - 2000 kg (depending on configuration).
Towing Capacity:
Varies significantly by engine and drivetrain, typically 1500 kg - 2500 kg.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited official global ratings for this specific generation; focused on structural integrity for its class.
Active Features
ABS:
Available on some higher trim levels or as an option.
Passive Features
Airbags:
Driver airbag standard on most models; passenger airbag optional or standard on later models.
Seatbelts:
3-point seatbelts, potentially with pre-tensioners on front seats.
💡 Technology Features
Infotainment
Entertainment System:
Basic AM/FM radio, CD player, or cassette player depending on trim level and market.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Connectivity Features:
Limited; typically basic audio inputs, no Bluetooth or advanced smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km or 6 months, depending on oil type and driving conditions (refer to manual for exact specification).
Timing Belt Replacement:
For engines equipped with a timing belt (e.g., some petrol variants), interval typically 80,000-100,000 km.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher for petrol, ACEA B3/B4 or API CF-4/CG-4 for diesel. Viscosity SAE 10W-30, 10W-40, or 15W-40 common (check manual).
Coolant Type:
Ethylene glycol based, typically a green or orange coolant (refer to manual for exact specification and mixture).
Transmission Fluid Type Auto:
Dexron III or equivalent (check manual).
Transmission Fluid Type Manual:
API GL-4, SAE 75W-90 or 80W-90 (check manual).
Differential Fluid Type:
API GL-5, SAE 80W-90 or 85W-140 (check manual).
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, U-joints, clutch wear, diesel injector pump seals (on older diesels).
Diesel Engine Specifics:
Potential for glow plug issues, turbocharger wear, and corrosion on early models.
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Legacy:
Mitsubishi has a long history of producing robust and capable pickup trucks dating back to the Colt T-Series in the 1960s.
Model Evolution
L200 Lineage:
The L200/Triton nameplate has been in production since the late 1970s, evolving through multiple generations with increasing refinement and capability.
Production
Production Period:
1996-2006 for the K60/K70 generation.
Manufacturing Locations:
Primarily Japan, also Thailand and other global assembly plants.
🏆 Awards & Recognition
Recognitions
Segment Awards:
The Mitsubishi Triton/L200 consistently received positive reviews for its ruggedness and utility in the pickup truck segment during its production years.
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