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Mitsubishi

Mitsubishi L200 Inc. Petrol & Diesel Engines 4G63 4G64 & 4D56 Complete Service Repair Workshop Manual 1996 1997 1998 1999 2000 2001

Mitsubishi L200 Inc. Petrol & Diesel Engines 4G63 4G64 & 4D56 Complete Service Repair Workshop Manual 1996 1997 1998 1999 2000 2001

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Vehicle data plateRef 410698
Brand
Mitsubishi
Vehicle
Truck
Models covered
4D56, 4G63, 4G64, L200, Misc
Years
1996, 1997, 1998, 1999, 2000, 2001
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
L200
Model Generation:
Second Generation (K70/K80/K90 Series)
Production Years Covered By Manual:
1996, 1997, 1998, 1999, 2000, 2001
👋 Introduction
Market Position
Vehicle Segment:
Compact Pickup Truck / Sport Utility Truck
Competitive Analysis
Key Competitors:
Toyota Hilux, Nissan D22/D40 Navara, Ford Ranger, Isuzu D-Max.
Key Features
Vehicle Strengths:
Robust construction, reliable engines (especially diesel), excellent off-road capability (4WD models), practical utility.
Manual Value Proposition:
Empowers owners and independent mechanics with the detailed technical information needed for accurate diagnosis and repair, reducing reliance on expensive dealerships.
📋 Manual Details
Coverage Areas
Engines Covered:
Petrol: 4G63 (2.0L), 4G64 (2.4L); Diesel: 4D56 (2.5L TDI/Turbo Diesel)
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Complete Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshaft, valve train, timing belts/chains, lubrication system, cooling system.
Engine Fuel System:
Fuel injection systems (MPI for petrol, TDI/Turbo Diesel), fuel pumps, injectors, fuel filters, throttle body, emissions controls (EGR, catalytic converter).
Engine Ignition System:
Spark plugs, ignition coils, distributor (where applicable), ignition timing, ECU control.
Transmission Manual:
Clutch system, gearbox overhaul, gear shift linkage, drive shafts, differentials.
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, electronic controls, ATF specifications and replacement.
Drivetrain:
4WD system operation, transfer case, front and rear axle servicing, hub bearings.
Suspension System:
Front independent suspension (torsion bar), rear leaf spring suspension, shock absorbers, control arms, ball joints, bushings.
Steering System:
Power steering pump, steering rack, tie rod ends, steering column.
Brake System:
Front disc brakes, rear drum brakes (or disc on some models), hydraulic system, ABS (where applicable), brake fluid specifications.
Electrical System:
Battery, charging system (alternator, starter), lighting system, fuses, relays, wiring diagrams, ECU, sensor diagnostics.
Body And Chassis:
Body panel removal and installation, door mechanisms, interior trim, chassis lubrication points, frame repair.
HVAC System:
Air conditioning system servicing, heater core, blower motor, refrigerant handling.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, battery checks, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, error code interpretation.
Repair Procedures:
Step-by-step instructions for component replacement and repair, including engine, transmission, suspension, brakes, and electrical systems.
Diagnostic Procedures:
Engine control module (ECM) diagnostics, sensor testing, actuator testing, multimeter usage, scan tool application (where applicable).
Rebuild Procedures:
Detailed instructions for complete engine and transmission rebuilds, including torque specifications and clearances.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including sensor data analysis, component actuation tests, and troubleshooting flowcharts.
Repair Complexity:
Covers everything from basic DIY maintenance to complex overhauls requiring specialized tools and knowledge.
Information Detail:
Detailed specifications, torque values, clearances, diagrams, and schematics for all covered systems.
📊 Manual Specifications
File Format
File Format Detail:
Searchable PDF with high-resolution diagrams and text.
Print Quality
Print Quality Recommendation:
Designed for digital viewing, but printable with clear, crisp output.
Binding Type
Binding Type For Digital:
N/A (Digital Download)
Paper Type
Paper Type For Printed:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Petrol Engine 1:
4G63 SOHC Inline-4, 2.0 Liters (1997cc)
Petrol Engine 2:
4G64 SOHC Inline-4, 2.4 Liters (2351cc)
Diesel Engine:
4D56 SOHC Inline-4, 2.5 Liters (2477cc) - Naturally Aspirated and Turbocharged variants.
Performance
4G63 Power Output Approx:
110-125 hp @ 5500-6000 rpm
4G64 Power Output Approx:
120-145 hp @ 5500-6000 rpm
4D56 Power Output Approx Na:
73 hp @ 4200 rpm
4D56 Power Output Approx Turbo:
90-115 hp @ 4000 rpm
Fuel System
Petrol Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Diesel Fuel Delivery:
Direct Injection, Bosch VE Rotary Pump (NA) or Rotary Turbo Injection Pump (Turbo)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission
Optional
Optional Transmission:
4-Speed Automatic Transmission
Features
Drive Options:
2WD (RWD), 4WD (Part-time with selectable 2WD/4WD)
📐 Dimensions
Exterior
Wheelbase Approx:
3000 mm (118.1 in)
Length Approx:
4655 mm (183.3 in) (Single Cab), 4955 mm (195.1 in) (Double Cab)
Width Approx:
1690 mm (66.5 in)
Height Approx:
1735 mm (68.3 in) (Single Cab)
Cargo
Bed Length Approx:
1800 mm (70.9 in) (Single Cab), 1500 mm (59.1 in) (Double Cab)
Weights
Curb Weight Approx:
1600 - 1900 kg (3527 - 4189 lbs), varies by configuration and engine
🛡️ Safety Features
Ratings
Crash Safety Notes:
Vehicle safety standards varied significantly by region and era; specific official crash ratings for this generation are not widely published.
Active Features
ABS:
Optional on some models, standard on higher trims later in the production run.
Passive Features
Airbags:
Driver airbag typically standard; passenger airbag optional or standard on higher trims/later years.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio, cassette player, or single-CD player. Optional CD changer. Limited to audio playback, often with basic speaker systems.
Driver Assistance
Driver Assistance Features:
Minimal by modern standards. Primarily focused on mechanical systems. ABS was an option.
Connectivity
Connectivity Features:
No modern connectivity features such as Bluetooth or USB integration. Optional power windows and door locks on higher trims.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type (refer to manual for specific engine recommendations).
Engine Oil Filter Replacement:
Replace with every oil change.
Timing Belt Replacement 4G6X:
Every 90,000 - 100,000 km (56,000 - 62,000 miles) or 5-6 years for 4G63/4G64 petrol engines.
Timing Belt Replacement 4D56:
Every 100,000 - 120,000 km (62,000 - 75,000 miles) or 5-6 years for 4D56 diesel engines (check manual for specific version).
Fluid Specifications
Engine Oil Spec Petrol:
API SG/SH/SJ or higher, SAE 10W-30, 10W-40, or 5W-30 (viscosity depends on climate, check manual).
Engine Oil Spec Diesel:
API CG-4 or CI-4, SAE 15W-40 or 10W-30 (check manual for specific engine and turbo requirements).
Coolant Specification:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent.
Brake Fluid Specification:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 Gear Oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Mitsubishi DiaQueen ATF SP-II or SP-III, or equivalent Dexron II/III compatible fluid.
Known Issues
Common Wear Items:
Front suspension bushings and ball joints, clutch wear, exhaust system rust, water pump seals, diesel glow plugs, turbocharger (on turbocharged models).
Diesel Specific Concerns:
Injection pump timing and wear, turbocharger seals, potential for head gasket issues on high-mileage engines.
📚 Vehicle History
Brand Heritage
Mitsubishi Truck Legacy:
Mitsubishi has a long history of producing robust and capable utility vehicles, tracing its lineage back to earlier pickups and commercial vehicles.
Model Evolution
L200 Evolution:
The L200 (also known as Triton in some markets) is a cornerstone of Mitsubishi's global pickup truck lineup, known for its durability and adaptability.
Production
Manufacturing Locations:
Primarily manufactured in Thailand, with production also in Japan and other global facilities.
🏆 Awards & Recognition
Recognitions
Market Reputation:
The L200 is generally regarded as a dependable and rugged workhorse, particularly favored in commercial and off-road applications.
Ratings
Owner Satisfaction Notes:
High marks for durability and capability, though comfort and refinement are not its primary strengths.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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