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Mitsubishi L200 Series Complete Workshop Service Repair Manual 2011

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Series Year: 2011 Codes Chassis Code: KA/KB (specific to generation, assumed for 2011 model year) Generation Generation Designation: Fourth Generation (2005-2015, commonly...
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Mitsubishi L200 Series Complete Workshop Service Repair Manual 2011
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200 Series
Year:
2011
Codes
Chassis Code:
KA/KB (specific to generation, assumed for 2011 model year)
Generation
Generation Designation:
Fourth Generation (2005-2015, commonly referred to as 'Triton' in many markets)
👋 Introduction
Market Position
Segment:
Compact Pickup Truck / Light Commercial Vehicle
Target Audience:
Fleet operators, commercial users, off-road enthusiasts, DIY mechanics, professional technicians
Competitive Analysis
Key Competitors 2011:
Toyota Hilux, Ford Ranger, Isuzu D-Max, Nissan Navara, Chevrolet Colorado
Key Features
Vehicle Strengths:
Robust chassis, reliable powertrains, excellent off-road capability (especially 4x4 variants), versatility as a workhorse and family vehicle.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to perform comprehensive maintenance and repairs, reducing reliance on expensive dealership services and extending vehicle lifespan.
📋 Manual Details
Coverage Areas
Market Coverage:
Global (specific markets may have regional variations, manual aims for comprehensive coverage)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Exhaust System, Lubrication System, Ignition System, Turbocharger System (if applicable)
Drivetrain:
Transmission (Manual & Automatic), Transfer Case, Driveshafts, Differentials, Axles
Chassis:
Suspension (Front & Rear), Steering System, Braking System (Front & Rear), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Lighting System, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), Audio System, HVAC Controls, SRS (Airbag) System
Body:
Body Panels, Doors, Windows, Mirrors, Seats, Interior Trim, Exterior Trim, Bumpers, Bed/Cargo Area
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Checks & Changes, Filter Replacements, Belt Inspections & Replacements
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs) Interpretation, Component Testing Procedures
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis & Repair, Body Panel Repair
Technical Specifications:
Torque Specifications, Clearances, Component Dimensions, Wiring Diagrams, Exploded Views
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and schematics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for efficient information retrieval.
Print Quality
Resolution:
High-resolution images and diagrams suitable for printing.
Printability:
Printable pages for on-site workshop use.
Binding Type
Binding Type:
N/A (Downloadable PDF)
Paper Type
Paper Type:
N/A (Downloadable PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4D56 (3.2L Diesel), 4G64 (2.4L Petrol), 6G72 (3.0L V6 Petrol - less common for L200)
Engine Type:
Inline 4-Cylinder (Diesel), Inline 4-Cylinder (Petrol), V6 (Petrol)
Displacement Diesel:
3.2 Liters (3200 cc)
Displacement Petrol:
2.4 Liters (2378 cc) or 3.0 Liters (2972 cc for V6)
Performance
Horsepower 4D56 Diesel:
Approx. 134-176 hp (depending on turbo/intercooler configuration)
Torque 4D56 Diesel:
Approx. 294-400 Nm (depending on configuration)
Horsepower 4G64 Petrol:
Approx. 126-134 hp
Torque 4G64 Petrol:
Approx. 200-205 Nm
Fuel System
Fuel Injection Diesel:
Common Rail Direct Injection (CRDI)
Fuel Type:
Diesel, Unleaded Petrol
Cooling System
Coolant Type:
Ethylene Glycol based antifreeze (refer to manual for specific Mopar/Mitsubishi specifications)
Lubrication System
Engine Oil Viscosity Diesel:
API CF-4 or higher, SAE 10W-30 or 15W-40 (refer to manual for precise spec)
Engine Oil Capacity 4D56:
Approx. 6.5 - 7.0 Liters (with filter change)
🔧 Transmission
Standard
Transmission Type Common:
5-speed Manual Transmission (R5M42/R5M4X series)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (V4A5A series)
Features
Drive System:
Rear-Wheel Drive (RWD) and Super Select 4WD (SS4)
Transfer Case Type:
Manual or Electronic engagement for 4WD systems (Super Select allows 4H, 4HLc, 4LLc engagement)
Fluid Specifications
Manual Transmission Fluid:
GL-4 SAE 75W-90 or SAE 80W-90 (refer to manual for precise spec)
Automatic Transmission Fluid:
DIA-Queen ATF SP-III or equivalent (refer to manual for precise spec)
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab
Wheelbase Typical:
3000 mm (approx.)
Length Typical:
4900 - 5200 mm (depending on cab and bed configuration)
Width Typical:
1750 - 1800 mm
Height Typical:
1770 - 1810 mm
Weights
Curb Weight Typical 4X4 Double Cab:
1800 - 2000 kg (approx.)
Gross Vehicle Weight Rating Gvwr:
Approx. 2800 - 3000 kg (varies by configuration)
🛡️ Safety Features
Ratings
Ancap Rating Common:
4 Stars (for certain configurations and testing periods, consult ANCAP for specifics)
Active Features
Braking System:
Front ventilated discs, Rear drums. ABS, EBD (Electronic Brakeforce Distribution) are common options/standard on higher trims.
Stability Control:
Traction Control (TCL) and Active Stability Control (ASC) available on some models, particularly later in the generation.
Passive Features
Airbags:
Front driver and passenger airbags are standard on most models. Side and curtain airbags may be optional or standard on higher trims.
Seatbelts:
Pre-tensioning seatbelts with force limiters.
💡 Technology Features
Infotainment
Audio System:
Base models often feature a basic AM/FM radio with CD player and auxiliary input. Higher trims may offer more advanced systems with MP3 playback, enhanced speaker systems, and potentially aftermarket navigation integration.
Driver Assistance
Cruise Control:
Available on higher trim levels, particularly with automatic transmissions.
Parking Sensors:
Available as an option or standard on some higher-spec Double Cab models.
Connectivity
Bluetooth:
May be available on premium audio systems in higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 km or 6 months (for severe use/diesel) or 10,000 km or 12 months (for normal use/petrol) – refer to manual for specific interval based on market and driving conditions.
Air Filter Replacement:
Typically every 20,000 - 40,000 km or as needed based on dusty conditions.
Fuel Filter Replacement Diesel:
Typically every 40,000 - 60,000 km, critical for diesel engine longevity.
Fluid Specifications
Coolant Capacity:
Approx. 8.5 - 9.0 Liters (refer to manual for exact capacity based on engine)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for precise specification)
Known Issues
Common Issues Diesel 4D56:
Cracked cylinder heads (in earlier versions/specific manufacturing batches), glow plug issues, turbocharger wear, injector problems (if maintenance neglected).
Common Issues General:
Leaf spring fatigue, exhaust system rust, potential for drive shaft universal joint wear, A/C system performance degradation over time.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Truck Lineage:
Mitsubishi has a long history of producing robust pickup trucks dating back to the Colt T-series in the 1960s, evolving through various generations of the Triton/Mighty Max/L200.
Model Evolution
Fourth Generation Focus:
The fourth generation (KA/KB) introduced a more car-like interior, improved aerodynamics, and advanced safety features compared to its predecessors. It maintained its strong reputation for durability and off-road prowess.
Production
Manufacturing Locations:
Primarily manufactured in Thailand (Laem Chabang Plant), with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Segment Recognition:
Consistently recognized for its durability, off-road capability, and value for money in the pickup truck segment across various global markets.
Ratings
Reliability Ratings:
Generally considered a reliable vehicle, especially the diesel variants, with strong ownership reviews often citing longevity and low cost of ownership when properly maintained.
Certifications
Emissions Compliance:
Compliant with relevant emissions standards for the model year and market of sale (e.g., Euro IV for diesel engines in many regions).
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