|
Basic Information
|
|
Identification
|
|
Make:
|
Mitsubishi
|
|
Model:
|
L200
|
|
Generation:
|
K50/K60/K70 Series (Third Generation)
|
|
Codes
|
|
Chassis Codes:
|
K51, K52, K53, K54, K55, K56, K57, K58, K59, K61, K62, K63, K64, K65, K66, K67, K68, K69, K71, K72, K73, K74, K75, K76, K77, K78, K79
|
|
Production Years:
|
1996-2007 (This manual covers 1998-2002 specifically)
|
|
Introduction
|
|
Market Position
|
|
Market Position:
|
The Mitsubishi L200 (also known as Triton, Strada, Mighty Max in some markets) of this era was a highly popular compact to mid-size pickup truck known for its robust build, reliable powertrains, and off-road capability, often used for commercial purposes as well as personal utility.
|
|
Competitive Analysis
|
|
Competitive Analysis:
|
Competed directly with other compact/mid-size pickups of the late 1990s and early 2000s such as the Toyota Hilux/Tacoma, Ford Ranger, Nissan D22/Frontier, Mazda B-Series, and Chevrolet S-10/Colorado.
|
|
Key Features
|
|
Key Features:
|
Body-on-frame construction, available 2WD and 4WD drivetrains, choice of single cab, extended cab, and double cab configurations, durable engines (petrol and diesel), practical cargo bed, often featuring rugged styling.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine Systems:
|
Engine mechanical (including teardown, assembly, troubleshooting for petrol and diesel engines), engine management (ECU, sensors, actuators), fuel injection systems, ignition systems, cooling systems, lubrication systems, exhaust systems, emission control systems.
|
|
Transmission Systems:
|
Manual and automatic transmissions (overhaul, adjustments, troubleshooting), transfer cases (4WD systems), drivelines, axles, CV joints.
|
|
Chassis Systems:
|
Suspension systems (front and rear, independent and solid axle depending on configuration), steering systems (power steering, steering column, linkage), braking systems (disc and drum, ABS components if equipped), wheel alignment specifications.
|
|
Electrical Systems:
|
Wiring diagrams, lighting systems, starting and charging systems, ignition systems, instrument cluster, power accessories (windows, locks, mirrors), body electrical components, fuse and relay locations, diagnostic trouble codes (DTCs).
|
|
Body And Frame:
|
Body panel removal and installation, interior trim, seating, glass replacement, chassis frame inspection and repair, tailgate/tailgate lift mechanisms, bumper systems.
|
|
Climate Control HVAC:
|
Air conditioning system (refrigerant types, pressures, component servicing, leak detection), heating system, and ventilation.
|
|
Procedures Included
|
|
Maintenance Procedures:
|
Scheduled maintenance (oil changes, filter replacements, fluid checks, belt tensioning), preventative maintenance tips, lubrication points, tire rotation, brake inspections.
|
|
Repair Procedures:
|
Step-by-step diagnostic and repair instructions for all major systems, including engine overhauls, transmission rebuilds, suspension component replacement, brake caliper servicing, electrical component diagnosis and replacement.
|
|
Troubleshooting Guides:
|
Diagnostic flowcharts and symptom-based troubleshooting for common and complex issues across all vehicle systems.
|
|
Technical Specifications:
|
Torque specifications for all fasteners, component clearances, fluid capacities, electrical specifications (voltages, resistance values), diagnostic parameter ranges.
|
|
Diagnostic Procedures:
|
Includes detailed diagnostic procedures for engine, transmission, electrical, and chassis faults, often utilizing symptom-based troubleshooting and specific test procedures for sensors and actuators.
|
|
Rebuild Procedures:
|
Covers complete rebuild procedures for engines, manual and automatic transmissions, differentials, and transfer cases, including part specifications and clearances.
|
|
Wiring Diagrams:
|
Detailed electrical wiring diagrams for all vehicle systems, allowing for accurate diagnosis and repair of electrical faults.
|
|
Technical Depth
|
|
Technical Depth:
|
Comprehensive, covering basic maintenance to complete engine and transmission overhauls, advanced electrical diagnostics, and chassis component repair.
|
|
Component Specifications:
|
Includes detailed component specifications, such as bearing clearances, piston ring end gap, valve stem heights, and gear lash specifications for major assemblies.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Options:
|
4G64 (2.4L SOHC I4 Petrol), 4G63 (2.0L I4 Petrol), 4G63T (2.0L Turbo I4 Petrol - performance variants), 4D56 (2.5L OHC I4 Diesel), 4D56T (2.5L Turbo I4 Diesel), 4M40 (2.8L OHC I4 Diesel), 4M41 (3.2L DOHC I4 Diesel - later models).
|
|
Performance
|
|
Horsepower Range:
|
Approx. 90 hp (naturally aspirated diesel) to 150+ hp (turbocharged petrol/diesel variants).
|
|
Torque Range:
|
Approx. 130 lb-ft (naturally aspirated diesel) to 250+ lb-ft (turbocharged diesel).
|
|
Fuel System
|
|
Fuel System Petrol:
|
Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPI).
|
|
Fuel System Diesel:
|
Indirect Injection (IDI) or Direct Injection (DI) with Turbocharging for most variants.
|
|
Engine Codes Examples
|
|
Engine Codes Examples:
|
4G64 SOHC 16V, 4D56T SOHC 8V Turbo Diesel.
|
|
Engine Codes Examples Diesel:
|
4D56 8V OHC Diesel, 4D56T 8V OHC Turbo Diesel, 4M40 8V OHC Diesel.
|
|
Maintenance
|
|
Service Intervals
|
|
Engine Oil Change Interval:
|
Every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type (refer to manual for exact specification).
|
|
Air Filter Replacement Interval:
|
Every 15,000-30,000 miles or annually, or more frequently in dusty conditions.
|
|
Fuel Filter Replacement Interval Diesel:
|
Every 20,000-40,000 miles, or as per manual, particularly important for diesel.
|
|
Timing Belt Replacement Interval:
|
For petrol engines with timing belts (e.g., 4G64): 60,000-90,000 miles or 5-7 years. Diesel engines (e.g., 4D56) often use timing chains or belts with longer intervals (refer to manual).
|
|
Transmission Fluid Change Interval:
|
Manual: Every 30,000-50,000 miles. Automatic: Every 30,000-50,000 miles or every 24-36 months, depending on usage. Check manual for specific intervals and conditions.
|
|
Fluid Specifications
|
|
Engine Oil Specification:
|
API SJ/SL, SAE 10W-30 or 10W-40 for petrol; SAE 15W-40 API CF-4/CG-4 for diesel (refer to specific engine and climate).
|
|
Coolant Specification:
|
Ethylene glycol-based antifreeze with water (50/50 mix), typically requiring a coolant meeting JIS K 2234 or similar standard.
|
|
Brake Fluid Specification:
|
DOT 3 or DOT 4 brake fluid.
|
|
Power Steering Fluid:
|
Dexron II/III or equivalent power steering fluid (refer to manual).
|
|
Known Issues
|
|
Known Issues Diesel:
|
Glow plug issues, injector pump wear, turbocharger failure (especially if poorly maintained), potential for head gasket failure on older/high-mileage 4D56 engines, rust in common areas like wheel arches and chassis rails.
|
|
Known Issues Petrol:
|
Head gasket issues on 4G64, ignition coil failures, alternator problems, exhaust manifold cracks on some turbo models.
|
|
Known Issues Chassis:
|
Wear in suspension bushings and ball joints, universal joint failure on driveshafts, rust on the frame and body, brake component wear (pads, rotors, calipers).
|
|
Known Issues Electrical:
|
Corrosion in electrical connectors, power window motor failure, instrument cluster issues (e.g., gauges). ABS sensor failures on equipped vehicles.
|
