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Mitsubishi L200 1998-2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 / Strada Codes Chassis Codes: K70 series (4WD), K60 series (2WD) Generation Generation Code: Third Generation (1996-2005, with facelift in 2001) 👋...
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Type: Truck
Vendor:
Sku: 370503
Mitsubishi L200 1998-2002 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200 / Strada
Codes
Chassis Codes:
K70 series (4WD), K60 series (2WD)
Generation
Generation Code:
Third Generation (1996-2005, with facelift in 2001)
👋 Introduction
Market Position
Vehicle Segment:
Compact Pickup Truck / Ute (Utility Vehicle)
Competitive Analysis
Key Competitors:
Toyota Hilux, Nissan Navara, Ford Ranger, Isuzu D-Max, Mazda B-Series
Key Features
Vehicle Strengths:
Robust construction, reliable powertrain options, capable 4WD system (Super Select 4WD-II on many models), good cargo utility, affordability.
📋 Manual Details
Coverage Areas
Covered Years:
1998, 1999, 2000, 2001, 2002
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Exhaust System, Drivetrain (including 4WD system)
Chassis:
Suspension (Front & Rear), Steering, Brakes (including ABS if equipped), Wheels & Tires
Electrical:
Battery, Charging System, Ignition System, Lighting, Instrumentation, Audio System, Wiper/Washer System, HVAC
Body:
Exterior Panels, Doors, Windows, Seats, Interior Trim, Body Sealing
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, tire rotation
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation
Repair And Rebuild:
Engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair
Adjustments:
Brake adjustments, clutch adjustments, headlight aim adjustment
Drivetrain Repair:
Transfer case overhaul, propeller shaft maintenance, differential servicing, CV joint replacement.
Brake System Repair:
Brake pad/shoe replacement, caliper/wheel cylinder servicing, brake line inspection and replacement, ABS component troubleshooting.
Bodywork Repair:
Information on door mechanism adjustments, window regulator repair, bumper alignment, and basic sheet metal repair.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complex diagnostics and major component overhauls. Includes detailed diagrams and specifications.
Wiring Diagrams:
Includes comprehensive electrical schematics for all major systems, facilitating troubleshooting of complex electrical faults.
Engine Rebuilding:
Detailed instructions for engine disassembly, inspection of components (pistons, rings, bearings, cylinder head), and reassembly with torque specifications.
Transmission Rebuilding:
Step-by-step guides for manual and automatic transmission overhaul, including clutch pack replacement, valve body inspection, and torque converter servicing.
Diagnostic Tools:
While primarily for mechanical systems, it will cover diagnostic procedures for engine control units (ECUs) and may reference specific scan tool functions or diagnostic connectors (e.g., MUT-II/III if applicable).
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear diagrams and text.
Print Quality
Scalability:
Pages are designed for clear printing and viewing on various devices.
Binding Type
Digital Format:
N/A (Digital Download)
Paper Type
Digital Medium:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63 (2.0L Petrol), 4G64 (2.4L Petrol), 4D56 (2.5L Diesel)
Displacement Petrol:
1997cc (2.0L), 2351cc (2.4L)
Displacement Diesel:
2477cc (2.5L)
Performance
Horsepower 2.0L Petrol:
Approx. 120-135 PS
Horsepower 2.4L Petrol:
Approx. 130-145 PS
Horsepower 2.5L Diesel:
Approx. 85-95 PS (Naturally Aspirated), 105-115 PS (Turbocharged)
Fuel System
Petrol Injection:
Multi-point Fuel Injection (MPI)
Diesel Injection:
Direct Injection (DI) / Indirect Injection (IDI) depending on variant; common rail not typically found in this generation
Engine Management
Ignition System:
Electronic Ignition (Distributorless on later models)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual
Optional
Automatic Transmission:
4-speed automatic
Features
4Wd System:
Part-time 4WD (2H, 4H, 4L) or optional Super Select 4WD-II (SS4-II) with full-time 4WD capability and differential lock
📐 Dimensions
Exterior
Wheelbase:
Approx. 3000 mm (Double Cab), 2550 mm (Single Cab)
Length:
Approx. 4945 mm (Double Cab), 4690 mm (Single Cab)
Width:
Approx. 1770 mm
Height:
Approx. 1715-1750 mm (depending on configuration)
Cargo
Bed Length:
Approx. 1835 mm (Single Cab), 1510 mm (Double Cab)
Weights
Curb Weight:
Approx. 1600-1900 kg (depending on configuration)
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by region and specific test. Generally considered robust for its class, but electronic safety aids were less common.
Active Features
Braking System:
Front Disc Brakes, Rear Drum Brakes. Optional ABS (Anti-lock Braking System) on higher trims.
Passive Features
Airbags:
Driver and passenger airbags were optional or standard on higher trims depending on the market.
Seatbelts:
3-point ELR seatbelts with pre-tensioners and force limiters on front seats.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM/Cassette or CD players were common. Higher trims might have optional CD changers or improved speaker systems.
Driver Assistance
Cruise Control:
Optional on higher trim levels.
Connectivity
Auxiliary Input:
Not typically available on factory units of this era; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Petrol:
Every 5,000 km or 3 months (using mineral oil), or 10,000 km or 6 months (using synthetic oil).
Oil Change Diesel:
Every 5,000 km or 3 months (using diesel engine oil).
Air Filter Replacement:
Every 20,000 km or 12 months.
Fuel Filter Replacement Diesel:
Every 40,000 km or 24 months.
Fluid Specifications
Engine Oil Petrol:
API SG/SH/SJ, SAE 10W-30 or 10W-40 (depending on temperature).
Engine Oil Diesel:
API CF/CG-4, SAE 15W-40 (or 10W-30 in colder climates).
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant) - typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 (or 75W-85 for some differentials).
Transmission Fluid Automatic:
Mitsubishi ATF SP-II or SP-III (or equivalent Dexron III/Mercon compatible fluid).
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Common Diesel Problems:
Glow plug issues, injector pump wear (especially on high-mileage units), turbocharger seal leaks, exhaust manifold cracks.
Common Petrol Problems:
Oil consumption on higher mileage engines (4G63/4G64), timing belt replacement is crucial (every 90,000-100,000 km), ignition coil issues.
Chassis Suspension:
Worn ball joints and tie rod ends due to load and off-road use, leaf spring fatigue on rear suspension.
Electrical:
Corrosion on electrical connectors (especially in humid climates), power window motor failures, dashboard indicator light issues.
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Legacy:
Mitsubishi has a long history of producing reliable and capable pickup trucks, dating back to the early models like the Colt T120, evolving into the Pajero Sport and L200/Strada lines.
Model Evolution
Third Generation Overview:
The third generation (1996-2005) introduced a more aerodynamic and car-like cabin design, improving comfort and usability. The 2001 facelift brought updated styling, including revised front-end design and new alloy wheel options.
Production
Manufacturing Locations:
Primarily manufactured in Thailand, with assembly in other global locations depending on market.
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently ranked as a popular choice in the compact pickup truck segment globally for its durability and value.
Ratings
Reliability Perception:
Generally considered a reliable vehicle, especially the diesel variants, when properly maintained. Known for its robust underpinnings.
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