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Mitsubishi L200 Truck Complete Workshop Service Repair Manual 2006 2007

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🏷️ Basic Information Identification Make: Mitsubishi Model: L200 Truck Model Alias: Triton (in some markets) Generation Generation Code: KB4T / KB7T Generation Years: 2005-2015 (Fourth Generation) Codes Chassis Code: KB4T...
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Mitsubishi L200 Truck Complete Workshop Service Repair Manual 2006 2007
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200 Truck
Model Alias:
Triton (in some markets)
Generation
Generation Code:
KB4T / KB7T
Generation Years:
2005-2015 (Fourth Generation)
Codes
Chassis Code:
KB4T (4x4), KB7T (4x2)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size pickup truck, often referred to as a lifestyle or utility vehicle.
Target Audience:
Individuals and businesses requiring a versatile, durable, and capable vehicle for work, recreation, and off-road use.
Competitive Analysis
Key Competitors:
Toyota Hilux, Ford Ranger, Isuzu D-Max, Nissan Navara, Chevrolet Colorado.
Key Features
Body Styles:
Single Cab, Extended Cab (Club Cab), Double Cab (Crew Cab).
Drivetrain Options:
Rear-wheel drive (4x2) and selectable/full-time four-wheel drive (4x4) with Super Select II system (in many markets).
📋 Manual Details
Coverage Areas
Market Coverage:
Global (specific to North American, European, Australian, and Asian markets where the L200/Triton was sold)
Trim Levels Covered:
All trim levels (e.g., GL, GLS, Exceed, Sports)
Page Count
Estimated Page Count:
1000+ pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual
Manual Purpose:
For diagnosis, repair, maintenance, and overhaul of the vehicle.
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, lubrication system, cooling system, exhaust system, engine control systems (ECU, sensors, actuators).
Transmission Drivetrain:
Manual transmission, automatic transmission, transfer case, drive shafts, differentials, axles, four-wheel-drive system.
Chassis Suspension:
Front suspension, rear suspension, steering system, braking system (ABS, EBD), wheels, tires, chassis frame.
Electrical Electronics:
12V electrical system, battery, charging system (alternator), starting system, lighting system (headlights, taillights, interior), instrument cluster, wiring diagrams, fuse box information, ECU pinouts.
Body Interior:
Body panels, doors, hoods, tailgates, glass, interior trim, seats, HVAC system, body control modules.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, diagnostic procedures for various systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, tire rotation, spark plug replacement, belt inspections and replacement.
Component Repair Overhaul:
Engine rebuild procedures, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack repair.
Diagnostic Procedures:
Step-by-step diagnostic routines for identifying faults in engine, transmission, brakes, electrical systems, etc.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems, including harness routing and connector pinouts.
Specifications Tolerances:
Torque specifications for fasteners, engine clearances, bearing tolerances, alignment specifications.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to full engine and transmission rebuilds).
Diagnostic Capability:
Advanced (covers diagnostic trouble codes, sensor data interpretation, and electronic system troubleshooting).
Diagnostic Tools Required:
Basic hand tools, specialized engine tools, diagnostic scan tools (e.g., MUT-III or compatible).
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval.
Print Quality
Image Resolution:
High-resolution diagrams, illustrations, and photographs for clarity.
Layout:
Professionally formatted with clear headings, step-by-step instructions, and organized data.
Binding Type
Binding Type For Print:
N/A (Digital Download)
Paper Type
Paper Type For Print:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4D56 (3.2L Diesel)
Engine Type:
In-line 4-cylinder, Turbocharged Diesel Common Rail Direct Injection
Displacement:
3200 cc (3.2 Liters)
Performance
Horsepower Common Range:
134 hp to 175 hp (depending on market and specific tune)
Torque Common Range:
314 Nm to 400 Nm (depending on market and specific tune)
Fuel System
Fuel Type:
Diesel
Injection System:
Common Rail Direct Injection (CRDI)
Engine Codes Alternatives
Alternative Engines:
4G64 (2.4L Petrol - less common in 2006-2007, more prevalent in earlier models or specific markets), 4M41 (3.2L DI-D Common Rail Diesel - also used).
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed or 5-speed Automatic Transmission (INVECS-II)
Features
Transfer Case:
Manual or Electronic (Super Select II 4WD system in higher trims).
📐 Dimensions
Exterior
Overall Length:
Varies by cabin type and bed length (approx. 4950-5300 mm)
Overall Width:
Approx. 1750-1800 mm
Overall Height:
Approx. 1775-1800 mm
Cargo
Bed Length Variants:
Standard Bed, Long Bed
Weights
Curb Weight:
Varies significantly by configuration (approx. 1700-2000 kg)
Gross Vehicle Weight Rating:
Approx. 2500-2900 kg
Towing Capacity:
Up to 3000 kg (braked trailer, market dependent)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Variable by region and testing authority (ANCAP, Euro NCAP - often 4-star for earlier models of this generation).
Active Features
Braking Systems:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD).
Traction Control:
Available on some higher trims (Traction Control System - TCS).
Passive Features
Airbags:
Driver and front passenger airbags (standard on most models). Side airbags and curtain airbags available on higher trims.
Seatbelts:
Three-point seatbelts with pretensioners for front seats.
Child Seat Anchors:
ISOFIX child seat anchorage points (availability varies by market/region).
💡 Technology Features
Infotainment
Audio System Options:
Factory-installed AM/FM radio with CD player, auxiliary input, and basic speaker systems. Higher trims may offer premium audio, MP3 playback, and steering wheel audio controls.
Navigation:
Optional GPS navigation systems available on higher trim levels or as dealer-installed accessories.
Driver Assistance
Cruise Control:
Available on select models and trim levels.
Rear Parking Sensors:
Available as an option or standard on higher trims.
Connectivity
Bluetooth:
Available on later models and higher trims for hands-free calling and audio streaming.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 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 based on inspection.
Fuel Filter Replacement:
Every 40,000-60,000 km for diesel models.
Coolant Replacement:
Initial replacement at 40,000 km or 24 months, then every 40,000 km or 24 months thereafter.
Fluid Specifications
Engine Oil Spec:
API CI-4 or higher, ACEA B4 for Diesel. Viscosity typically 5W-30, 10W-30, or 10W-40 depending on ambient temperature (consult manual).
Engine Oil Capacity:
Approx. 7.5 - 8.5 Liters (for 3.2L diesel, including filter).
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (check manual for specific type).
Transmission Fluid Automatic:
Mitsubishi Genuine ATF SP-II M or equivalent.
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent (ethylene glycol based, blue color).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Maintenance Concerns:
Timing belt wear (if applicable to specific engine variant), diesel particulate filter clogging (on later models with DPF), EGR valve issues, glow plug failure in cold climates, suspension component wear (bushings, ball joints).
Common Electrical Concerns:
Alternator issues, starter motor problems, electrical connector corrosion in humid climates.
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Lineage:
Mitsubishi has a long history of producing rugged and capable pickup trucks dating back to the Colt T120 in the 1960s, evolving through models like the L200/Forte, and later the Triton/L200.
Model Evolution
Fourth Generation Introduction:
The fourth generation (KB4T/KB7T) was introduced globally in 2005, marking a significant redesign with a more modern and integrated body-on-frame chassis, improved aerodynamics, and enhanced interior comfort.
Facelifts:
Received minor updates and facelifts during its production run, including revised front grilles, bumpers, and interior trim enhancements.
Production
Production Years For Model:
2005-2015
Major Production Sites:
Thailand (Laem Chabang Plant), Philippines, Egypt, Brazil.
🏆 Awards & Recognition
Recognitions
Pickup Of The Year Awards:
The L200/Triton platform has received numerous awards in various markets for its reliability, utility, and value over the years, though specific 'pickup of the year' awards for the 2006-2007 model year would be market-specific.
Ratings
Safety Ratings General:
Generally rated as a capable and safe vehicle within its class, though safety standards and testing evolve, impacting comparative ratings.
Certifications
Emission Standards Compliance:
Compliant with prevailing emission standards for the model years 2006 and 2007 in its respective markets (e.g., Euro III, Euro IV).
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