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Mitsubishi L200 2005-2014 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 / Triton / Strada (depending on market) Generation Generation Code: KB4T / KB7T (often referred to as the fourth generation) Codes Chassis Codes: KB4T, KB7T 👋 Introduction Market Position Segment: Mid-size pickup truck / Light commercial vehicle Target Audience: Commercial users, fleet operators, off-road enthusiasts, DIY mechanics Competitive Analysis Key Competitors: Toyota Hilux, Ford Ranger, Nissan Navara, Isuzu D-Max Key Features Vehicle Strengths: Robust construction, reliable diesel engines, excellent off-road capability, versatile cargo bed, good towing capacity 📋 Manual Details Coverage Areas Regions Covered: Global (specifics may vary by market, but manual provides comprehensive technical data applicable to the model range) Page Count Page Count: 3818 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (4D56, 4M41), Transmission (Manual, Automatic), Drivetrain (4WD systems, differentials, driveshafts) Chassis: Suspension (front independent, rear leaf spring), Steering, Brakes (front discs, rear drums/discs), Wheels and Tires Electrical: Wiring diagrams, lighting, charging system, starting system, engine control unit (ECU), body control modules (BCM), comfort features Body: Exterior body panels, interior trim, doors, glass, seating, body sealing Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), symptom-based diagnostics Repair: Component removal and installation, engine overhaul, transmission repair, brake caliper replacement, suspension component refurbishment Technical Specifications: Torque specifications, clearances, alignment data, component tolerances Technical Depth Depth: Comprehensive: from basic fluid checks and replacements to in-depth engine rebuilds, transmission overhauls, and complex electrical system diagnosis. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (OCR applied) Print Quality Resolution: High-resolution scans for clarity of text and diagrams Binding Type Binding Type: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: 4D56 (2.5L Diesel) Engine Description 1: 2.5-liter turbocharged common rail direct injection (CRDi) diesel engine Power Output 1: Typically 134 hp (99 kW) to 176 hp (130 kW) depending on tune and intercooler. Torque Output 1: Typically 314 Nm (231 lb-ft) to 400 Nm (295 lb-ft) depending on tune. Secondary Engine Engine Code 2: 4M41 (3.2L Diesel) Engine Description 2: 3.2-liter turbocharged common rail direct injection (CRDi) diesel engine Power Output 2: Typically 163 hp (120 kW) to 178 hp (131 kW). Torque Output 2: Typically 343 Nm (253 lb-ft) to 440 Nm (325 lb-ft). Fuel System Fuel Type: Diesel Injection System: Common Rail Direct Injection (CRDi) Performance Emission Standards: Euro III, Euro IV (depending on market and specific model year) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed or 5-speed Automatic Transmission (Invvecs-II Sport Mode) Features Drivetrain Options: Rear-Wheel Drive (RWD) and Easy Select 4WD / Super Select 4WD Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (e.g., Mitsubishi Genuine Manual Transmission Fluid) Automatic Transmission Fluid: DIA QUEEN ATF-SP II M or equivalent 📐 Dimensions Exterior Length: Approx. 5000-5150 mm (depending on body style) Width: Approx. 1750-1800 mm Height: Approx. 1775-1800 mm Cargo Cargo Bed Length: Varies by cabin configuration (single cab, double cab), approx. 1325 mm to 1805 mm Weights Curb Weight: Approx. 1750 kg - 2050 kg (depending on configuration) Gross Vehicle Weight Rating: Approx. 2700 kg - 3000 kg Towing Capacity: Up to 2500 kg (braked trailer, depending on market regulations) 🛡️ Safety Features Ratings Ancap Rating: Varies by market and testing year. Some variants achieved 4 or 5 stars for occupant protection. Active Features ABS: Standard on most variants E Brake Force Distribution: EBD (Electronic Brake-force Distribution) Brake Assist: BA (Brake Assist) available on some models Passive Features Airbags: Driver and front passenger airbags standard on most models; side airbags and curtain airbags available on higher trims. Seatbelts: Pre-tensioning seatbelts with force limiters Child Seat Anchors: ISOFIX/LATCH points available on specific seating positions 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with CD player, MP3 compatibility and speakers. Higher trims may offer upgraded audio systems and navigation. Display Screen: Optional touchscreen display for navigation and multimedia on higher-spec models. Driver Assistance Cruise Control: Available on higher trim levels. Parking Sensors: Rear parking sensors available as an option on some models. Connectivity Bluetooth: Available on later models and higher trim levels for hands-free calling. Usb Aux Input: Available on some models for audio device connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 km to 10,000 km or 6 months, whichever comes first (refer to manual for exact specification based on operating conditions). Air Filter Replacement: Every 20,000 km to 40,000 km or annually, depending on driving environment. Fuel Filter Replacement: Every 30,000 km to 60,000 km (critical for common rail diesels). Fluid Specifications Engine Oil Spec: API CF-4 / CH-4 / CI-4 or ACEA B3/B4, viscosity SAE 15W-40 or 5W-40...
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Mitsubishi L200 2005-2014 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200 / Triton / Strada (depending on market)
Generation
Generation Code:
KB4T / KB7T (often referred to as the fourth generation)
Codes
Chassis Codes:
KB4T, KB7T
👋 Introduction
Market Position
Segment:
Mid-size pickup truck / Light commercial vehicle
Target Audience:
Commercial users, fleet operators, off-road enthusiasts, DIY mechanics
Competitive Analysis
Key Competitors:
Toyota Hilux, Ford Ranger, Nissan Navara, Isuzu D-Max
Key Features
Vehicle Strengths:
Robust construction, reliable diesel engines, excellent off-road capability, versatile cargo bed, good towing capacity
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specifics may vary by market, but manual provides comprehensive technical data applicable to the model range)
Page Count
Page Count:
3818
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4D56, 4M41), Transmission (Manual, Automatic), Drivetrain (4WD systems, differentials, driveshafts)
Chassis:
Suspension (front independent, rear leaf spring), Steering, Brakes (front discs, rear drums/discs), Wheels and Tires
Electrical:
Wiring diagrams, lighting, charging system, starting system, engine control unit (ECU), body control modules (BCM), comfort features
Body:
Exterior body panels, interior trim, doors, glass, seating, body sealing
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs), symptom-based diagnostics
Repair:
Component removal and installation, engine overhaul, transmission repair, brake caliper replacement, suspension component refurbishment
Technical Specifications:
Torque specifications, clearances, alignment data, component tolerances
Technical Depth
Depth:
Comprehensive: from basic fluid checks and replacements to in-depth engine rebuilds, transmission overhauls, and complex electrical system diagnosis.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (OCR applied)
Print Quality
Resolution:
High-resolution scans for clarity of text and diagrams
Binding Type
Binding Type:
Not applicable (Digital Download)
Paper Type
Paper Type:
Not applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4D56 (2.5L Diesel)
Engine Description 1:
2.5-liter turbocharged common rail direct injection (CRDi) diesel engine
Power Output 1:
Typically 134 hp (99 kW) to 176 hp (130 kW) depending on tune and intercooler.
Torque Output 1:
Typically 314 Nm (231 lb-ft) to 400 Nm (295 lb-ft) depending on tune.
Secondary Engine
Engine Code 2:
4M41 (3.2L Diesel)
Engine Description 2:
3.2-liter turbocharged common rail direct injection (CRDi) diesel engine
Power Output 2:
Typically 163 hp (120 kW) to 178 hp (131 kW).
Torque Output 2:
Typically 343 Nm (253 lb-ft) to 440 Nm (325 lb-ft).
Fuel System
Fuel Type:
Diesel
Injection System:
Common Rail Direct Injection (CRDi)
Performance
Emission Standards:
Euro III, Euro IV (depending on market and specific model year)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed or 5-speed Automatic Transmission (Invvecs-II Sport Mode)
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Easy Select 4WD / Super Select 4WD
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (e.g., Mitsubishi Genuine Manual Transmission Fluid)
Automatic Transmission Fluid:
DIA QUEEN ATF-SP II M or equivalent
📐 Dimensions
Exterior
Length:
Approx. 5000-5150 mm (depending on body style)
Width:
Approx. 1750-1800 mm
Height:
Approx. 1775-1800 mm
Cargo
Cargo Bed Length:
Varies by cabin configuration (single cab, double cab), approx. 1325 mm to 1805 mm
Weights
Curb Weight:
Approx. 1750 kg - 2050 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 2700 kg - 3000 kg
Towing Capacity:
Up to 2500 kg (braked trailer, depending on market regulations)
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by market and testing year. Some variants achieved 4 or 5 stars for occupant protection.
Active Features
ABS:
Standard on most variants
E Brake Force Distribution:
EBD (Electronic Brake-force Distribution)
Brake Assist:
BA (Brake Assist) available on some models
Passive Features
Airbags:
Driver and front passenger airbags standard on most models; side airbags and curtain airbags available on higher trims.
Seatbelts:
Pre-tensioning seatbelts with force limiters
Child Seat Anchors:
ISOFIX/LATCH points available on specific seating positions
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player, MP3 compatibility and speakers. Higher trims may offer upgraded audio systems and navigation.
Display Screen:
Optional touchscreen display for navigation and multimedia on higher-spec models.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Rear parking sensors available as an option on some models.
Connectivity
Bluetooth:
Available on later models and higher trim levels for hands-free calling.
Usb Aux Input:
Available on some models for audio device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 km to 10,000 km or 6 months, whichever comes first (refer to manual for exact specification based on operating conditions).
Air Filter Replacement:
Every 20,000 km to 40,000 km or annually, depending on driving environment.
Fuel Filter Replacement:
Every 30,000 km to 60,000 km (critical for common rail diesels).
Fluid Specifications
Engine Oil Spec:
API CF-4 / CH-4 / CI-4 or ACEA B3/B4, viscosity SAE 15W-40 or 5W-40 (depending on climate and specific engine variant - check manual for exact specs)
Coolant Type:
Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant with organic acid technology (OAT).
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear (manual transmission), suspension bushings and ball joints, exhaust system components, diesel particulate filter (DPF) clogging (if equipped).
Engine Specific Concerns:
Turbocharger issues (if not maintained properly), injector problems in high-mileage diesels, glow plug failures in cold climates.
Electrical Gremlins:
Occasional issues with window regulators, central locking, or dashboard warning lights can occur with age; troubleshooting covered in manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, Japan
Model Evolution
Generation Period:
2005-2014
Platform:
Shared platform with related SUVs and pickups from Mitsubishi, often considered a robust and utilitarian design.
Production
Assembly Locations:
Primarily Thailand (Laem Chabang Plant), also other locations globally depending on market distribution.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
The L200/Triton has received various 'Pickup of the Year' and '4x4 of the Year' awards in different markets globally during its production run.
Ratings
Off Road Capability Ratings:
Consistently praised for its robust chassis, reliable 4WD system, and respectable ground clearance, making it a strong performer in off-road reviews.
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