Mitsubishi L200 Triton Pickup Workshop Service Repair Manual 1996-2015 PDF Download - MMTBSL200OMES.zip
Full service and repair guide, complete with Electrical Wiring Diagrams, covering the Mitsubishi L200 (Triton) pickup trucks from 1996 through 2015 — packed with every technical detail you need to service, troubleshoot, fix, and rebuild your truck the way a professional would.
The 1996-2015 Mitsubishi L200 (Triton) pickup workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,133 pages
File Format: PDF / ISO disc image (Windows 32-bit)
Language: English
TABLE OF CONTENTS
00.pdf..1
GENERAL..1
01.pdf..3
GENERAL..3
HOW TO USE THIS MANUAL..4
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS..4
DEFINITION OF TERMS..4
INDICATION OF TIGHTENING TORQUE..4
MODEL INDICATIONS..4
EXPLANATION OF MANUAL CONTENTS..5
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS..7
CONTENTS OF TROUBLESHOOTING..7
Diagnosis method..8
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS..8
3. DIAGNOSIS FUNCTION..8
4. DIAGNOSIS CODE CHART..8
5. DIAGNOSIS CODE PROCEDURES..8
6. TROUBLE SYMPTOM CHART..8
7. SYMPTOM PROCEDURES..9
8. SERVICE DATA REFERENCE TABLE..9
9. ACTUATOR TEST TABLE..9
10. CHECK AT ECU TERMINALS..9
11. INSPECTION PROCEDURE BY USING AN OSCILLOSCOPE..9
DIAGNOSIS FUNCTION..9
HOW TO READ DIAGNOSIS CODE..9
ERASING DIAGNOSIS CODE..9
HOW TO USE THE INSPECTION PROCEDURES..10
CURRENT TROUBLE..11
PAST TROUBLE..11
HARNESS CHECK..11
MEASURES TO TAKE AFTER REPLACING THE ECU..11
CONNECTOR MEASUREMENT SERVICE POINTS..12
CONNECTOR INSPECTION SERVICE POINTS..13
INSPECTION SERVICE POINTS FOR A BLOWN FUSE..14
HOW TO COPE WITH INTERMITTENT MALFUNCTIONS..14
HOW TO TREAT PAST TROUBLE..15
VEHICLE IDENTIFICATION..15
VEHICLE NAME PLATE..15
MODEL CODE..17
CHASSIS NUMBER..18
ENGINE MODEL STAMPING..19
GENERAL DATA AND SPECIFICATIONS..19
CLUB CAB..19
2WD..19
4WD..21
DOUBLE CAB..22
2WD..22
4WD..24
PRECAUTIONS BEFORE SERVICE..25
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER..25
WHAT THE COMMON RAIL ENGINE LEARNS..26
REGISTRATION AND LEARNING PROCEDURE..26
INJECTOR IDENTIFICATION CODE REGISTRATION PROCEDURE..26
PURPOSE..26
REGISTRATION PROCEDURE..27
SMALL INJECTION QUANTITY LEARNING PROCEDURE..27
PURPOSE..27
LEARNING PROCEDURE..28
SUPPLY PUMP CORRECTION LEARNING PROCEDURE..28
PURPOSE..28
LEARNING PROCEDURE FOR IDLING..29
SERVICING ELECTRICAL SYSTEM..29
VEHICLES WITH SEMI AUTOMATIC AIR CONDITIONER..29
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS..29
VEHICLE WASHING..29
PRE-INSPECTION CONDITION..29
MULTI USE TESTER (M.U.T.-III) SUB ASSEMBLY..30
HOW TO USE THE THROTTLE CONTROLLER..30
IN ORDER TO PREVENT VEHICLES FROM FIRE..31
ENGINE OILS..31
HEALTH WARNING..31
RECOMMENDED PRECAUTIONS..31
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..32
SRS SERVICE PRECAUTIONS..33
SUPPORT LOCATIONS FOR LIFTING AND JACKING..35
2WD..35
4WD..36
2WD..37
4WD..38
STANDARD PART/TIGHTENING-TORQUE TABLE..39
11.pdf..41
ENGINE..41
11A.pdf..43
ENGINE MECHANICAL 4D5-SOHC..43
GENERAL INFORMATION..44
SERVICE SPECIFICATIONS..44
SEALANTS..45
SPECIAL TOOLS..46
ON-VEHICLE SERVICE..48
DRIVE BELT TENSION CHECK AND ADJUSTMENT..48
ALTERNATOR DRIVE BELT TENSION CHECK AND ADJUSTMENT..48
POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK..49
A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT..50
VALVE CLEARANCE CHECK AND ADJUSTMENT..50
INJECTION TIMING CHECK AND ADJUSTMENT..52
IDLE SPEED CHECK..54
COMPRESSION PRESSURE CHECK..54
TIMING BELT TENSION ADJUSTMENT..55
TIMING BELT B TENSION ADJUSTMENT..56
CRANKSHAFT PULLEY..57
REMOVAL AND INSTALLATION..57
REMOVAL SERVICE POINTS..58
INSTALLATION SERVICE POINT..59
CAMSHAFT AND VALVE STEM SEAL..60
REMOVAL AND INSTALLATION..60
REMOVAL SERVICE POINTS..61
INSTALLATION SERVICE POINTS..62
OIL PAN AND OIL SCREEN..64
REMOVAL AND INSTALLATION..64
REMOVAL SERVICE POINTS..65
INSTALLATION SERVICE POINTS..65
CRANKSHAFT OIL SEAL..67
REMOVAL AND INSTALLATION..67
REMOVAL SERVICE POINT..68
INSTALLATION SERVICE POINTS..68
CYLINDER HEAD GASKET..69
REMOVAL AND INSTALLATION..69
REMOVAL SERVICE POINTS..70
INSTALLATION SERVICE POINTS..71
TIMING BELT..73
REMOVAL AND INSTALLATION..73
REMOVAL SERVICE POINT..74
INSTALLATION SERVICE POINTS..74
TIMING BELT B..76
REMOVAL AND INSTALLATION..76
REMOVAL SERVICE POINT..76
INSTALLATION SERVICE POINT..77
ENGINE ASSEMBLY..78
REMOVAL AND INSTALLATION..78
REMOVAL SERVICE POINTS..80
INSTALLATION SERVICE POINT..80
12.pdf..81
ENGINE LUBRICATION..81
GENERAL INFORMATION..82
ENGINE OILS..82
SERVICE SPECIFICATION..82
SEALANTS..82
LUBRICANTS..83
SPECIAL TOOLS..83
ON-VEHICLE SERVICE..83
ENGINE OIL CHECK..83
ENGINE OIL REPLACEMENT..83
ENGINE OIL FILTER REPLACEMENT..84
OIL PRESSURE CHECK..86
ENGINE OIL COOLER..87
REMOVAL AND INSTALLATION 4D5-SOHC..87
REMOVAL AND INSTALLATION 4D5-DOHC..88
INSTALLATION SERVICE POINT..88
REMOVAL AND INSTALLATION 4M4..89
INSTALLATION SERVICE POINTS..90
15.pdf..91
INTAKE AND EXHAUST..91
SERVICE SPECIFICATIONS..92
SPECIAL TOOL..93
ON-VEHICLE SERVICE..94
TURBOCHARGER SUPERCHARGING PRESSURE CHECK..94
WASTE GATE ACTUATOR CHECK..95
AIR CLEANER..96
REMOVAL AND INSTALLATION 4D5-SOHC..96
REMOVAL AND INSTALLATION 4D5-DOHC, 4M4..97
INTERCOOLER 4D5-DOHC,4M4..98
REMOVAL AND INSTALLATION..98
INSTALLATION SERVICE POINT..98
INLET AND EXHAUST MANIFOLDS 4D5-SOHC..99
REMOVAL AND INSTALLATION 4D5-SOHC..99
INLET MANIFOLD..101
REMOVAL AND INSTALLATION 4D5-DOHC..101
REMOVAL SERVICE POINT..102
INSTALLATION SERVICE POINT..102
REMOVAL AND INSTALLATION 4M4..103
EXHAUST MANIFOLD AND TURBOCHARGER..104
REMOVAL AND INSTALLATION 4D5-DOHC..104
INSTALLATION SERVICE POINTS..105
REMOVAL AND INSTALLATION 4M4..106
INSTALLATION SERVICE POINTS..107
TURBOCHARGER ASSEMBLY 4D5-SOHC..108
REMOVAL AND INSTALLATION 4D5-SOHC..108
INSTALLATION SERVICE POINT..109
EXHAUST PIPE, MAIN MUFFLER AND CATALYTIC CONVERTER 4D5-SOHC..109
REMOVAL AND INSTALLATION 4D5-SOHC..109
EXHAUST PIPE AND MAIN MUFFLER 4D5-DOHC, 4M4..110
REMOVAL AND INSTALLATION..110
31.pdf..111
WHEEL AND TYRE..111
GENERAL INFORMATION..112
SERVICE SPECIFICATIONS..112
TROUBLESHOOTING..113
DIAGNOSIS..113
WHEEL BALANCE ACCURACY..114
PURPOSE..114
PROCEDURE BALANCING TIPS..115
CONFIRMING PROPER BALANCE..115
WHEEL BALANCER CALIBRATION CHECKS..116
WHEEL BALANCER CALIBRATION CHECKING FLOW CHART..117
ON-VEHICLE SERVICE..118
TYRE INFLATION PRESSURE CHECK..118
TYRE WEAR CHECK..118
WHEEL RUNOUT CHECK..118
WHEEL AND TYRE..118
INSTALLATION SERVICE POINT..118
SPARE TYRE CARRIER..119
REMOVAL AND INSTALLATION..119
33.pdf..121
FRONT SUSPENSION..121
GENERAL INFORMATION..122
SPECIFICATIONS..123
SERVICE SPECIFICATIONS..123
SPECIAL TOOLS..124
ON-VEHICLE SERVICE..125
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT 2WD..125
FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT 4WD..126
CAMBER AND CASTER REFERENCE TABLE..127
LOWER ARM BALL JOINT AXIAL PLAY CHECK..128
LOWER ARM BALL JOINT COVER CHECK..128
UPPER ARM ASSEMBLY..129
REMOVAL AND INSTALLATION 2WD..129
REMOVAL SERVICE POINT..130
REMOVAL AND INSTALLATION 4WD..131
REMOVAL SERVICE POINT..132
INSTALLATION SERVICE POINT..132
INSPECTION..132
SHOCK ABSORBER AND COIL SPRING..133
REMOVAL AND INSTALLATION..133
REMOVAL SERVICE POINT..134
INSTALLATION SERVICE POINT..134
INSPECTION..134
SHOCK ABSORBER ASSEMBLY..135
REMOVAL AND INSTALLATION 4WD..135
INSPECTION..135
DISASSEMBLY AND REASSEMBLY 4WD..136
DISASSEMBLY SERVICE POINTS..136
REASSEMBLY SERVICE POINTS..137
INSPECTION..138
LOWER ARM..139
REMOVAL AND INSTALLATION 2WD..139
REMOVAL SERVICE POINT..139
REMOVAL AND INSTALLATION 4WD..140
REMOVAL SERVICE POINT..141
INSPECTION..141
LOWER ARM BUSHING REPLACEMENT 2WD..142
LOWER ARM BUSHING REPLACEMENT 4WD..142
STRUT BAR 2WD..144
REMOVAL AND INSTALLATION..144
INSTALLATION SERVICE POINT..144
STABILIZER BAR 4WD..145
REMOVAL AND INSTALLATION..145
INSTALLATION SERVICE POINTS..145
INSPECTION..145
34.pdf..147
REAR SUSPENSION..147
GENERAL INFORMATION..148
SPECIFICATIONS..149
SHOCK ABSORBER ASSEMBLY..150
REMOVAL AND INSTALLATION..150
2WD..150
4WD..151
INSTALLATION SERVICE POINT..151
INSPECTION..152
42.pdf..153
BODY..153
HOOD..155
ON-VEHICLE SERVICE..155
ADJUSTMENT OF CLEARANCE AROUND HOOD..155
ADJUSTMENT OF ALIGNMENT OF HOOD STEPPED PORTION AND HOOD STRIKER..155
ADJUSTMENT OF HOOD HEIGHT..155
HOOD..156
REMOVAL AND INSTALLATION..156
FENDER..157
SPECIAL TOOL..157
FENDER..158
REMOVAL AND INSTALLATION..158
REMOVAL SERVICE POINT..159
INSTALLATION SERVICE POINT..159
FUEL FILLER LID..160
REMOVAL AND INSTALLATION CLUB CAB..160
REMOVAL AND INSTALLATION DOUBLE CAB..161
SPLASH SHIELD..162
REMOVAL AND INSTALLATION..162
WINDOW GLASS..163
ADHESIVE..163
SPECIAL TOOL..163
GENERAL..163
WINDOW GLASS INSTALLATION..164
WINDSHIELD..165
REMOVAL AND INSTALLATION..165