Market Position:
The L200 (also known as Triton in some markets) was a popular light commercial vehicle, particularly valued for its ruggedness, utility, and off-road capability in the pickup truck segment. This manual caters to owners and mechanics working on this versatile workhorse.
Competitive Analysis:
Competed against vehicles like the Toyota Hilux, Nissan D22 Navara, Isuzu D-Max, and Ford Ranger during its production run. Its strengths often lay in its specific powertrain options and Mitsubishi's reputation for durability.
Key Features:
Robust chassis, versatile load-carrying capacity, reliable diesel and gasoline engine options, capable 4WD systems, and a relatively simple yet effective mechanical design, making it a favored vehicle for commercial use and adventure.
Coverage Areas:
Comprehensive service and repair for the 1997-2002 Mitsubishi L200 (including various body styles and drivetrain configurations).
Page Count:
Estimated 1000+ pages (typical for comprehensive factory service manuals).
Manual Type:
Factory Service Manual / Workshop Manual / Repair Manual
Language:
English (assumed based on typical sales, could vary)
Format:
Digital (likely PDF, potentially printable)
Systems Covered:
Engine (mechanical and electrical), Lubrication System, Fuel System, Cooling System, Intake and Exhaust Systems, Engine Electrical, Engine and Emission Control, Clutch, Manual Transmission, Drivetrain (4WD systems, drive shafts, differentials), Braking System, Steering System, Suspension System, Body Electrical, HVAC System, Body Panels and Interior, Frame and Chassis.
Procedures Included:
Scheduled maintenance, routine inspections, diagnosis and troubleshooting, component removal and installation, repair procedures, adjustments, torque specifications, electrical system diagnostics, wiring diagrams, fluid capacities and specifications, overhaul procedures for major components.
Technical Depth:
In-depth technical information suitable for professional technicians and experienced DIY enthusiasts, covering everything from basic fluid changes to complete engine and transmission rebuilds and advanced electrical troubleshooting.
Primary Engine:
4G63 2.0L SOHC I4 (Gasoline), 4D56 2.5L SOHC Turbocharged I4 Diesel.
Horsepower Gasoline:
Approx. 133 hp @ 6000 rpm (4G63, depending on specific variant and market)
Torque Gasoline:
Approx. 175 Nm @ 4500 rpm (4G63, depending on specific variant and market)
Horsepower Diesel:
Approx. 103 hp @ 4000 rpm (4D56 Turbo Diesel, depending on specific variant and market)
Torque Diesel:
Approx. 240 Nm @ 2000 rpm (4D56 Turbo Diesel, depending on specific variant and market)
Fuel System Gasoline:
Multi-point Fuel Injection (MPI)
Fuel System Diesel:
Direct Injection (DI) with Turbocharging and Intercooler
Wheelbase:
Varies by body style (e.g., Single Cab, Double Cab), typically around 2900 mm to 3000 mm.
Overall Length:
Varies by body style, commonly 4550 mm to 5100 mm.
Overall Width:
Approx. 1690 mm to 1750 mm.
Overall Height:
Approx. 1600 mm to 1750 mm.
Curb Weight:
Approx. 1500 kg to 1800 kg (depending on configuration).
Gross Vehicle Weight Rating Gvwr:
Approx. 2400 kg to 2700 kg.
Safety Ratings:
No formal crash test ratings like NCAP were prevalent for this vehicle class and era. Safety features were basic.
Active Features:
Standard braking system (front disc, rear drum), potentially optional ABS on higher trims or later models in the range.
Passive Features:
Seat belts, reinforced cabin structure, potentially driver's airbag on certain export models or higher trims. Basic construction prioritizes utility over advanced safety.
Infotainment System:
Basic for its era. Likely featured an aftermarket or factory radio with AM/FM, cassette player, and possibly CD player on higher trims. No integrated navigation or touchscreens.
Driver Assistance Features:
Minimal. ABS was an option on higher trims. No electronic stability control, traction control, or advanced driver-assistance systems (ADAS) were available.
Connectivity Options:
None beyond basic radio antenna. Aux input or Bluetooth would require aftermarket integration.
Oil Change Interval:
Typically every 5,000-10,000 km or 6 months, depending on driving conditions and oil type. Refer to manual for specific recommendations.
Air Filter Replacement:
Every 20,000-40,000 km or as needed, especially in dusty environments.
Fuel Filter Replacement Diesel:
Every 40,000-60,000 km for diesel models.
Engine Oil Type:
API SG or higher, SAE 10W-30 or 15W-40 (diesel), SAE 5W-30/10W-30/10W-40 (gasoline). Consult manual for precise viscosity and API classification.
Coolant Type:
Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water. Mitsubishi DiaQueen Super Long Life Coolant (SLLC) compatible, or equivalent.
Transmission Fluid Manual:
GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron II or III compatible ATF (Automatic Transmission Fluid).
Differential Fluid:
GL-5 SAE 80W-90 hypoid gear oil.
Known Issues Diesel Engine:
Overheating due to potential radiator blockages or faulty thermostats, turbocharger wear, injector issues, timing belt replacement diligence (4D56 is a timing belt engine). Head gasket failures can occur if regularly overheated.
Known Issues Gasoline Engine:
Oil consumption on higher mileage units, valve stem seal wear, potential head gasket issues if maintenance is neglected. The 4G63 is generally robust but requires proper servicing.
Known Issues Drivetrain:
Wear in U-joints, differential seals, and transfer case components, especially with off-road use. Clutch wear is typical for manual transmissions used in utility roles.
Known Issues Suspension:
Leaf spring fatigue on rear suspension, worn ball joints and tie rod ends on front suspension due to load and road conditions.
Known Issues Body:
Rust, particularly around wheel arches, chassis members, and door bottoms, especially in areas with harsh weather or road salt. Interior trim can show wear.
Brand Heritage:
Mitsubishi has a long history of producing robust and capable commercial vehicles and SUVs, dating back to the early Pajero and truck lines. The L200 lineage is a core part of their utility vehicle offerings.
Model Evolution:
The third generation L200 (K50/K60/K70) was a significant evolution, featuring a more modern and aerodynamic design compared to its predecessors. It offered various cab configurations (single, club, double) and bed lengths, enhancing its market appeal.
Production Years:
1996-2005 (This generation).
Manufacturing Locations:
Primarily produced in Japan, Thailand, and various other international assembly plants by Mitsubishi Motors.
