Systems Covered:
Engine mechanical (4G63, 4G64, 6G72, 4D56, 4M40 - specify based on actual engine options), fuel system, ignition system, cooling system, lubrication system, exhaust system, engine control (ECU), manual transmission, automatic transmission, transfer case, front axle, rear axle, driveshafts, suspension (front and rear), steering system, brake system (front discs, rear drums/discs), anti-lock braking system (ABS), power steering, body electrical system (lighting, wipers, horn, power windows, locks), climate control system (HVAC), interior trim, exterior body panels, chassis components, diagnostic trouble codes (DTCs).
Engine Mechanical:
Complete overhaul and repair procedures for all specified engine variants (4G63, 4G64, 6G72, 4D56, 4M40). Includes cylinder head assembly, piston/ring installation, crankshaft/bearing service, camshaft timing, valve clearance adjustment, oil pump, and oil pan removal/installation.
Fuel And Emission Systems:
Fuel injection system diagnosis and repair, fuel pump testing, injector service, fuel filter replacement, emissions control system (EGR, catalytic converter, O2 sensors) diagnosis and servicing.
Cooling And Lubrication:
Radiator and cooling fan service, water pump replacement, thermostat replacement, heater core service, oil cooler service (if applicable), oil pan and oil filter replacement, lubrication point identification.
Electrical System:
Complete wiring diagrams for all systems, charging system (alternator, starter), ignition system (coils, spark plugs, control modules), lighting system (headlights, taillights, interior lights), instrumentation cluster, power windows, power locks, central locking, wipers, horn, fuse box and relay identification, diagnostic procedures for electrical faults.
Transmission Drivetrain:
Manual and automatic transmission disassembly, assembly, and repair. Clutch system service (clutch disc, pressure plate, release bearing). Transfer case service and repair. Front and rear differential service. Driveshaft and CV joint inspection and replacement. Wheel bearing replacement.
Suspension Steering:
Front and rear suspension component inspection, replacement, and alignment procedures. Shock absorber/strut replacement. Leaf spring inspection/replacement (rear). Steering system diagnosis (rack and pinion or steering box), power steering pump and hose replacement, tie rod end replacement. Wheel alignment specifications.
Brake System:
Front disc brake service (pads, rotors, calipers). Rear drum brake service (shoes, drums, wheel cylinders) or rear disc brake service (pads, rotors, calipers). Brake fluid flush and bleeding procedures. ABS system diagnosis and component testing. Parking brake adjustment.
Body And Chassis:
Body panel repair and replacement, door assembly, latch and lock mechanisms, interior trim removal and installation, glass replacement, bumper repair, chassis component inspection and repair, frame straightening (if applicable), mounting points.
Climate Control HVAC:
Air conditioning system diagnosis and repair, refrigerant handling (referencing safety protocols), compressor service, evaporator and condenser service, blower motor replacement, heater control valve, cabin air filter replacement (if equipped).
Procedures Included:
Routine maintenance (oil changes, filter replacements, fluid checks/changes, tune-ups), troubleshooting guides for common and uncommon faults, diagnostic procedures, component removal and installation, disassembly and assembly of major components (engine, transmission, differentials, suspension arms, brake calipers), electrical system diagnosis and repair, wiring diagrams, torque specifications for critical fasteners, lubrication procedures, body repair guidelines, emissions control system servicing, HVAC system servicing, wheel alignment procedures, brake bleeding, clutch adjustment/replacement.
Engine Diagnostics:
Detailed troubleshooting charts based on symptoms, diagnostic trouble code (DTC) lookup and interpretation, sensor testing (e.g., MAP, TPS, O2, crank/cam sensors), ECU diagnostics.
Transmission Diagnostics:
Automatic transmission fluid level and condition checks, shift solenoid testing, torque converter diagnostics, manual transmission clutch engagement/disengagement checks.
Suspension Steering Diagnostics:
Checking for play in steering components, diagnosing suspension noise, checking for alignment issues, wheel balance and tire wear analysis.
Brake System Diagnostics:
Checking for brake fade, pulsating brakes, parking brake function, brake fluid leaks, ABS warning light diagnosis.
Body Repair Procedures:
Dent removal, panel alignment, rust repair techniques, door panel removal for access, trim piece replacement.
Electrical Troubleshooting:
Using multimeters to test circuits, tracing wiring faults, diagnosing intermittent electrical issues, checking grounds, fuse and relay testing.
Engine Rebuild:
Detailed steps for engine disassembly, cleaning, inspection of internal components, machining recommendations (honing, grinding), reassembly with specified torque values and clearances, timing belt replacement procedures.
Transmission Overhaul:
Step-by-step instructions for disassembling, inspecting, replacing worn parts (seals, clutches, bands, gears), and reassembling manual and automatic transmissions.
Torque Specifications:
Extensive list of critical torque specifications for engine components, transmission fasteners, suspension mounting points, brake calipers, wheel hubs, and more.
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs (e.g., timing belt tensioner tools, seal installers, press tools).
Technical Depth:
Designed for professional technicians, offering in-depth diagnostic information, detailed repair procedures, component specifications, and schematics. Suitable for complex repairs and system overhauls, as well as routine maintenance and troubleshooting for skilled DIY mechanics.
Diagnostic Tools Required:
While basic diagnostics can be performed with hand tools and a multimeter, advanced diagnostics for engine control units (ECUs) would require a compatible OBD-I or potentially early OBD-II scan tool, depending on the specific ECU's capabilities and compliance for the 1995 model year. The manual will detail diagnostic connector locations and required tools.
Exterior Dimensions:
Dimensions vary based on body style (short/long wheelbase, high/low roof). Typical lengths ranged from approximately 4,600mm to 4,900mm, widths around 1,700mm-1,750mm, and heights from 1,900mm to 2,200mm. Ground clearance also varied significantly with 4WD models.
Interior Dimensions:
The L400 is known for its exceptionally spacious and flexible interior, capable of seating up to 8 passengers comfortably in many configurations. The van-like body allows for significant headroom and legroom.
Cargo Capacity:
Cargo capacity is highly configurable, offering substantial volume for goods or equipment, especially with rear seats folded or removed. Specific volume figures would depend on seating configuration.
Curb Weight:
Curb weight typically ranged from approximately 1,700 kg to 2,200 kg, depending on engine, drivetrain, and body configuration.
Gross Vehicle Weight Rating:
GVWR figures will vary depending on the specific L400 model and configuration (e.g., van, cargo, passenger). Typically ranges from 2,500 kg to 3,000 kg. Consult the manual or vehicle placard.
Towing Capacity:
Towing capacity figures would be specified by Mitsubishi and depend on engine, drivetrain, and braking system. Generally capable of towing moderate loads. Refer to manual or local regulations.
Service Intervals:
Typical intervals for oil changes: 5,000-10,000 km (3,000-6,000 miles) or 6-12 months. Air filter, fuel filter, spark plugs, and coolant should be replaced at intervals specified in the manual, often ranging from 20,000 km to 60,000 km. Timing belt replacement (if applicable, especially for non-interference engines) is critical, typically around 80,000-100,000 km. Refer to the manual for precise intervals based on engine type and driving conditions.
Engine Oil Specifications:
Gasoline engines typically require 10W-30 or 5W-30 API SG/SH or higher. Diesel engines often use 15W-40 or 10W-30 API CF-4 or higher. Specific viscosity and API service category should be confirmed in the manual. Engine oil capacity typically around 4.5-5.5 liters.
Transmission Fluid Specifications:
Manual transmissions typically require GL-4 gear oil (e.g., SAE 75W-90). Automatic transmissions usually require ATF SP-II M or similar Dexron/Mercon compatible fluids. Transfer case and differential fluid usually API GL-5 SAE 75W-90 or 80W-90. Capacities vary, check manual.
Coolant Specifications:
Requires a 50/50 mixture of ethylene glycol-based antifreeze and distilled water. Consult manual for specific type and capacity (typically 8-12 liters).
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid is typically specified. Consult the manual for the exact type and change interval.
Power Steering Fluid Specification:
Typically uses ATF Dexron II or III compatible fluid. Check manual for precise specification.
Common Issues:
Common issues may include wear in suspension bushings and ball joints due to vehicle weight and usage, potential for overheating on higher mileage diesel engines, injector pump issues on diesel models, radiator leaks, AC system performance degradation, and interior trim wear. The 4WD system, while robust, requires regular maintenance of its fluids and components. Timing belt failure can be catastrophic if not replaced on schedule (if applicable to the engine variant).
Rust Corrosion Points:
Common areas for rust on vehicles of this age and type can include wheel arches, rocker panels, door bottoms, and the underside of the chassis, especially in areas with road salt. The manual may offer guidance on rust prevention or repair.
Glow Plug Failure Diesel:
Diesel variants (4D56, 4M40) are susceptible to glow plug failure, impacting cold starting. The manual will cover testing and replacement procedures for glow plugs and the associated control system.
Turbocharger Issues Diesel:
Turbocharged diesel engines may experience issues with turbocharger wear or failure if not properly maintained, particularly regarding oil changes and avoiding excessive idling after hard use. Manual will detail turbo inspection.