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Mitsubishi L400 1995 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: L400 Year: 1995 Product Type: Repair Service Manual Codes Chassis Code: PA4W/PB4W/PC4W (Chassis codes may vary based on specific configuration, refer to VIN...
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Mitsubishi L400 1995 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L400
Year:
1995
Product Type:
Repair Service Manual
Codes
Chassis Code:
PA4W/PB4W/PC4W (Chassis codes may vary based on specific configuration, refer to VIN for exact identification)
👋 Introduction
Market Position
Market Position:
The Mitsubishi L400 (also known as Mitsubishi Delica Space Gear in many markets) was a versatile light commercial vehicle and passenger van, popular for its ruggedness, off-road capability, and spacious interior. This manual targets owners and technicians seeking to maintain and repair these vehicles.
Competitive Analysis
Competitive Analysis:
Competed with vehicles like the Toyota Hiace, Nissan Urvan/Caravan, and Ford Econovan. Its unique chassis and drivetrain options, particularly the Super Select 4WD system and available diesel engines, set it apart.
Key Features
Key Features:
Renowned for its robust construction, capable 4WD systems, and versatile interior configurations. The L400's ability to serve as a family vehicle, camper, or work van contributed to its appeal.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive coverage for all mechanical and electrical systems of the Mitsubishi L400 1995. Includes engine, transmission, drivetrain, brakes, suspension, steering, body electrical, climate control, and bodywork.
Page Count
Page Count:
Estimated 1500-2500 pages (typical for a full factory service manual, specific page count not provided in product info)
Manual Type
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
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
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
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.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, ensuring clarity of text, diagrams, and images. Printable pages for workshop use.
Binding Type
Binding Type:
Not applicable (Digital Download)
Paper Type
Paper Type:
Not applicable (Digital Download)
Completeness
Manual Completeness:
A comprehensive Factory Service Manual (FSM) equivalent, providing full repair and maintenance coverage. Not a condensed or simplified version.
Searchability
Searchable Text:
The PDF format is expected to be text-searchable, allowing for quick location of specific topics or components.
⚙️ Engine Specifications
Primary Engine
Primary Engine Options:
Likely includes naturally aspirated and turbocharged gasoline engines such as the 2.4L 4G64 SOHC (G64B) and 3.0L V6 6G72 SOHC (6G72), as well as diesel engines like the 2.5L 4D56 8-valve SOHC (4D56) and 2.8L 4M40 8-valve SOHC (4M40). Specific engine availability depends on market and trim level.
Performance
Horsepower Torque:
Horsepower and torque figures vary significantly by engine. For example, the 4G64 typically produced around 130-140 HP, the 6G72 V6 around 170-180 HP, the 4D56 diesel around 80-90 HP, and the 4M40 diesel around 90-105 HP. Torque figures would also vary accordingly. Refer to specific engine sections in the manual for exact specifications.
Compression Ratio:
Varies by engine; for example, 4G64 might have a ratio around 9.5:1, 6G72 around 8.9:1, 4M40 diesel around 21:1. Specific figures are in the manual.
Fuel System
Fuel System:
Gasoline engines utilize multi-point fuel injection (MPI). Diesel engines use indirect injection (IDI) or direct injection (DI) systems, often with turbocharging and intercooling for diesel variants.
Fuel Type Required:
Unleaded gasoline for gasoline engines. Diesel fuel for diesel engines. Octane rating requirements will be specified for gasoline engines.
Engine Codes
Common Engine Codes:
Gasoline: 4G63, 4G64, 6G72. Diesel: 4D56, 4M40. Specific engine code must be confirmed from the vehicle's VIN or engine bay placard.
🔧 Transmission
Standard
Standard Transmission:
Likely a 5-speed manual transmission for most variants.
Optional
Optional Transmission:
Likely a 4-speed automatic transmission (e.g., F4A42 or V4A51) for many models, especially higher trim levels or specific market configurations.
Features
Transmission Features:
Many L400 models featured Mitsubishi's renowned Super Select 4WD system, offering selectable 2WD, 4WD High, 4WD Low, and 4WD with locked center differential, providing exceptional traction and versatility.
Gear Ratios
Gear Ratios:
Gear ratios for both manual and automatic transmissions, as well as transfer case low-range ratios, will be detailed in the manual. These vary by transmission model and configuration.
📐 Dimensions
Exterior
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
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
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.
Weights
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.
🛡️ Safety Features
Ratings
Safety Ratings:
Specific crash test ratings for the 1995 L400 are not readily available from major agencies like NHTSA or IIHS. However, being a commercial/utility vehicle, emphasis was on structural integrity and occupant protection within the standards of the time.
Rollover Resistance:
As a van/SUV-style vehicle, particularly with higher roof options, stability and rollover resistance are important considerations. The manual may contain information regarding driving in crosswinds or on inclines.
Active Features
Active Safety Features:
Optional Anti-lock Braking System (ABS) was available on some models. Power-assisted brakes were standard. 4WD systems enhance active safety through improved traction.
Passive Features
Passive Safety Features:
Standard seat belts for all occupants. Reinforced body structure. Some models may have featured driver and passenger airbags (less common on base models of this era).
💡 Technology Features
Infotainment
Infotainment System:
Base models typically featured a basic AM/FM radio with cassette player. Higher trims might have offered CD players or more advanced stereo systems. Speaker configuration varies by trim. Satellite navigation was not common for this era.
Speaker Configuration:
Speaker count and placement varied significantly. Common configurations included 2-4 speakers in the front doors and possibly 2 more in the rear or overhead panels. Higher trims might offer more.
Driver Assistance
Driver Assistance Features:
Limited driver assistance features for the 1995 model year. ABS was an option. Cruise control may have been available on higher trims. Primary driver assistance relies on the 4WD system and good visibility.
Connectivity
Connectivity Options:
No integrated Bluetooth, USB ports, or smartphone connectivity. Connectivity would be aftermarket additions (e.g., Bluetooth FM transmitters or aftermarket head units).
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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.
Known Issues
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.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history of producing rugged and capable vehicles, including light commercial vehicles and SUVs. The L400 built upon this legacy.
Model Evolution
Model Evolution:
The L400 succeeded the L300 series and represented a significant redesign, adopting a more modern, cab-over-engine (or slightly forward control) design. It remained in production for several years with various facelifts and powertrain updates.
Generations:
The L400 represents the second generation of Mitsubishi's mid-size van/MPV series, following the L300. It was distinct from the smaller L200/Triton and larger L300/Starwagon in terms of chassis and design.
Production
Production Years:
1994-2007 (though the 1995 model year falls within the initial production run).
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Recognitions And Ratings:
The Mitsubishi L400/Delica Space Gear series gained a cult following and positive recognition for its off-road capability and go-anywhere nature, particularly among outdoor enthusiasts and adventurers. Specific awards from automotive publications for this generation are not widely documented.
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