🏷️ Basic Information

Make:

Mitsubishi

Model:

L200

Generation:

Third Generation

Chassis Codes:

K5T, K6T, K7T

Engine Codes:

4G63 (2.0L Petrol), 4G64 (2.4L Petrol), 4D56 (2.5L Diesel), 4M40 (2.8L Diesel)

👋 Introduction

Segment:

Compact Pickup Truck / Utility Vehicle

Target Audience:

Commercial users, adventurers, families seeking rugged utility, DIY mechanics.

Key Competitors:

Toyota Hilux, Nissan Navara (D22), Isuzu D-Max, Mazda BT-50 (earlier generations).

Body Styles:

Single Cab, Club Cab (Extended Cab), Double Cab (Crew Cab).

Drivetrain Options:

2WD (RWD), 4WD (4x4) with selectable or full-time 4WD systems.

Reputation:

Known for durability, reliability, and off-road capability, particularly with diesel engines.

📋 Manual Details

Covered Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002

Page Count:

Hundreds of pages (exact count not specified, typical for comprehensive factory manuals)

Manual Type:

Workshop Service Repair Manual

Language:

English (assumed, standard for these manuals)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, cylinder head, pistons, crankshaft, timing, lubrication, cooling system, fuel system (petrol and diesel), exhaust system.

Engine Management:

Ignition system, fuel injection (EFI/DI), emission control systems, diagnostic trouble codes (DTCs), sensor and actuator testing.

Transmission Drivetrain:

Manual and automatic transmission overhaul, clutch, transfer case, drive shafts, differentials (front and rear), hub bearings.

Suspension Steering:

Independent front suspension, leaf spring rear suspension, steering gear, power steering system, wheel alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (or disc on some models), hydraulic system, parking brake, ABS (if equipped) troubleshooting and repair.

Electrical System:

Battery, charging system (alternator), starting system, lighting, wipers, horn, power windows, central locking, interior and exterior electrical components, wiring diagrams.

Body Chassis:

Body construction, panel removal/installation, doors, hood, tailgate, interior trim, chassis frame inspection and repair, seat adjustments.

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling (where applicable).

Maintenance:

Routine maintenance checks, oil change intervals, filter replacement, spark plug replacement, belt replacement, fluid checks and top-ups.

Troubleshooting:

Diagnostic procedures for common and uncommon faults across all major systems, symptom-based troubleshooting guides.

Repair:

Step-by-step repair procedures for all components, including detailed disassembly and reassembly instructions.

Diagnostics:

On-board diagnostics (OBD-II) information, diagnostic tool usage, signal voltage and resistance checks, sensor calibration.

Overhaul:

Complete engine, transmission, and differential overhaul procedures with detailed part specifications and clearances.

Technical Specifications:

Torque specifications for all fasteners, engine data, gear ratios, fluid capacities, electrical resistance values, dimensions.

Depth:

Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchability:

Typically searchable text within the PDF for easy information retrieval.

Print Quality:

High-resolution scans, suitable for printing individual pages or the entire manual.

Binding Type:

Not applicable (PDF download)

Paper Type:

Not applicable (PDF download)

⚙️ Engine Specifications

Petrol Options:

2.0L 4G63 SOHC MPI (approx. 110-120 hp), 2.4L 4G64 SOHC MPI (approx. 130-140 hp).

Diesel Options:

2.5L 4D56 SOHC Naturally Aspirated Diesel (approx. 80-85 hp), 2.8L 4M40 SOHC Turbo Diesel (approx. 100-125 hp).

Torque Diesel 4M40:

Approximately 240-260 Nm (177-192 lb-ft) for the 2.8L Turbo Diesel.

Petrol Fuel System:

Multi-Point Fuel Injection (MPI).

Diesel Fuel System:

Indirect Injection (IDI) for 4D56, Direct Injection (DI) for 4M40 Turbo Diesel.

Coolant Type:

Ethylene glycol-based antifreeze (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent).

Engine Oil Grade:

API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific viscosity based on temperature).

Bore Stroke 4G63:

81.0 mm x 80.5 mm

Bore Stroke 4M40:

91.1 mm x 95.0 mm

🔧 Transmission

Standard Transmission:

5-speed manual transmission.

Optional Transmission:

4-speed automatic transmission (common on petrol and some diesel variants).

Transfer Case:

Part-time 4WD system with 2H, 4H, 4L (low range) engagement, or full-time 4WD with center differential on select models.

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 (check manual for precise specification and capacity).

Automatic Transmission Fluid:

Mitsubishi DiaQueen ATF-II or equivalent.

📐 Dimensions

Overall Length:

Varies by body style and market, typically around 4700-5000 mm.

Overall Width:

Approximately 1750-1800 mm.

Overall Height:

Approximately 1700-1750 mm (unladen).

Bed Length:

Varies significantly by cab configuration and market, but generally optimized for utility.

Curb Weight:

Typically ranging from 1500 kg to 1900 kg depending on configuration and engine.

Gross Vehicle Weight Rating Gvwr:

Up to approximately 2500-2800 kg.

🛡️ Safety Features

Crash Test Ratings:

Generally not subjected to modern stringent crash test standards due to its era and segment, but built with a robust ladder frame construction.

ABS:

Anti-lock Braking System (ABS) available as an option on some higher-trim models or later production years.

Airbags:

Driver airbag typically standard on most markets, passenger airbag optional or not available on base models.

Seatbelts:

3-point seatbelts with pre-tensioners available on front seats.

💡 Technology Features

Audio System:

Basic AM/FM radio with cassette player or single-disc CD player, often with 2-4 speakers.

Display:

Simple analog gauges and dashboard warning lights. No central infotainment screen.

Cruise Control:

Optional on higher trim levels, primarily on petrol models.

Connectivity Options:

Minimal, typically limited to basic 12V power outlet for accessories.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 km (3,000 miles) or 6 months for older specifications, or 10,000 km (6,000 miles) or 12 months for synthetic oils (always consult manual for specific engine).

Air Filter Replacement:

Every 20,000 km (12,000 miles) or annually, or more frequently in dusty conditions.

Fuel Filter Replacement Diesel:

Every 40,000 km (24,000 miles) or as recommended.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

DEXRON II or equivalent ATF.

Diesel Glow Plugs:

Glow plug failure can lead to hard starting in cold weather, especially on the 4D56.

Turbo Diesel Maintenance:

Turbocharger requires proper warm-up and cool-down periods; oil changes are critical for longevity.

Rear Leaf Springs:

Can sag over time with heavy loads, affecting ride height and handling.

Rust Corrosion:

As with many trucks of this era, frame and body rust can be an issue in humid or salt-prone environments.

Drive Shaft Universal Joints:

Universal joints can wear out, leading to clunking noises during acceleration or deceleration.

📚 Vehicle History

Mitsubishi Trucks:

Mitsubishi has a long history of producing robust and capable pickup trucks, dating back to early models like the Mitsubishi Forte.

L200 Lineage:

The L200 nameplate has been in continuous production since the late 1970s, evolving through multiple generations. This third generation (1996-2006) marked a significant design update with more modern styling and improved comfort.

Production Locations:

Primarily manufactured in Japan (Okazaki Plant) and also assembled in various international plants through CKD (Completely Knocked Down) kits.

🏆 Awards & Recognition

Utility Vehicle Awards:

While specific awards for this generation are not widely publicized in the same vein as modern SUVs, the L200 consistently received accolades in various markets for its ruggedness and value proposition in the utility segment.