Mitsubishi MOTORS L200 1996 Pickup Truck Manuals

Mitsubishi MOTORS L200 1996 Pickup Truck Manuals

Manuals and User Guides for Mitsubishi MOTORS L200 1996 Pickup Truck. We have 1 Mitsubishi MOTORS L200 1996 Pickup Truck manual available for free PDF download: Workshop Manual

Mitsubishi MOTORS L200 1996 Workshop Manual

Mitsubishi MOTORS L200 1996 Workshop Manual (1723 pages)

Brand: Mitsubishi MOTORS | Category: Automobile | Size: 32 MB

Table of Contents

Contents
2
Engine
3
Fuel
4
Service Brakes
5
Interior and Supplemental Restraint System
6
Heater, Air Conditioner and Ventilation
7
General
8
Scope of Maintenance, Repair and Servicing Explanations
10
On-Vehicle Service
10
Definition of Terms
10
Standard Value
10
Model Indications
11
Explanation of Manual Contents
12
Maintenance and Servicing Procedures
12
Classifications of Major Maintenance/Service Points
12
Symbols for Lubrication, Sealants and Adhesives
12
Basic Brake System
13
Headlamp Relay Continuity Inspection
13
Removal Service Points
13
Power Steering Gear Box
13
How to Use Troubleshooting/Inspection Service Points
14
Troubleshooting Contents
14
Standard Flow of Diagnosis Troubleshooting
14
System Operation and Symptom Verification Tests
14
When Using the Mut-II
15
Method of Reading Diagnosis Codes
15
Diagnosis Function
15
When Using the Warning Lamp
16
Indication of Diagnosis Code by Warning Lamp
16
Method of Erasing Diagnosis Codes
16
Applicable Systems
16
How to Use the Inspection Procedures
17
Harness Inspection
17
Measures to Take after Replacing the Ecu
17
If Inspecting with the Connector Disconnected
18
Waterproof Connectors
18
If Inspecting with the Connector Connected
18
Connector Measurement Service Points
18
Connector Inspection
19
Visual Inspection
19
Connector Pin Inspection
19
Connector Engagement Inspection
19
Inspection Service Points for a Blown Fuse
20
Points to Note for Intermittent Malfunctions
20
Inspection and Service before Fording a Stream
21
Treatment Before/After the Fording of a Stream
21
Inspection and Service after Fording a Stream
23
Vehicle Identification
24
Vehicle Information Code Plate
24
Code Plate Description
24
Model Code
24
Model Code
26
Table of Contents
27
Chassis Number
27
Engine Model Number
28
Major Specifications
29
2WD Single Cab
29
2WD Double Cab, Club Cab
30
4WD Single Cab, Club Cab
31
4WD Double Cab
32
Precautions before Service
33
Supplemental Restraint System (Srs)
33
Items to Follow When Servicing SRS
33
Vehicle Washing
34
Pre-Inspection Condition
34
Application of Anti-Corrosion Agents and Undercoats
34
Servicing the Electrical System
34
Mut-II
35
In Order to Prevent Vehicles from Fire
35
Engine Oils
35
Health Warning
35
General Information
37
Srs Service Precautions
38
Garage Jack
40
Axle Stands
40
Support Positions for a Garage Jack and Axle Stands
40
Support Locations for Lifting and Jacking
40
Double-Post Lift
42
Single-Post Lift
42
H-Bar Lift
42
Standard Parts-Tightening-Torque Table
44
Standard Bolt and Nut Tightening Torque
44
Flange Bolt and Nut Tightening Torque
44
Service Bulletin
65
Continent
73
- Engine Lubrication
  75
- Outline of Changes
  75
- Body
  77
- Input Signal Inspection Procedure
  77
- Etacs Function Adjustment Procedure
  77
- Inspection Chart for Trouble Symptoms
  78
- Inspection Procedure for Trouble Symptoms
  79
- MUT-II Pulse Check
  80
- Encrypted Codes Cannot be Registered
  81
- How to Replace a Battery of the Transmitter
  82
- Secret Code Registration Method
  82
- Ignition Switch
  83
- Keyless Entry System
  84
- Keyless Entry Receiver-ECU Removal Steps
  84
- Interior
  85
- Front Seat Belt
  85
- Outer Seat Belt Removal Steps
  85
- Inner Seat Belt Removal Steps
  85
- High-Mounted Stop Lamp
  87
- Chassis Electral
  87
- Indication of Tightening Torque
  89
Vehicle Identification
90
Country
91
- <4G6> Engine
  100
- General Information
  102
- Service Specifications
  102
- Sealant
  104
- Special Tools
  104
  - Alternator Drive Belt Tension Adjustment
    106
  - Alternator Drive Belt Tension Check
    106
- Drive Belt Tension Check and Adjustment
  106
- On-Vehicle Service
  106
  - Power Steering Oil Pump Drive Belt Tension Check and Adjustment
    107
  - Air Conditioner Compressor Drive Belt Tension Check and Adjustment
    108
- Ignition Timing Check and Adjustment
  109
- Idle Mixture Check
  110
- Idle Speed Check
  110
- Compression Pressure Check
  111
- Manifold Vacuum Check
  112
- Lash Adjuster Check
  113
  - Aa" Camshaft Sprocket Removal
    115
  - Camshaft Oil Seal
    115
  - "BA Camshaft Sprocket Installation
    116
  - AA Camshaft Oil Seal Installation
    116
  - Ab" Camshaft Oil Seal Removal
    116
  - Ca Camshaft Sprocket Spacer Installation
    117
  - Oil Pan and Oil Screen
    118
  - AA Oil Pan Installation
    119
  - AA" Oil Pan Removal
    119
  - BA Drain Plug Gasket Installation
    119
  - Cylinder Head Gasket
    120
  - AB" Cylinder Head Assembly Removal
    122
  - Aa Cylinder Head Gasket Installation
    123
  - Ba Cylinder Head Assembly Installation
    123
  - Ca Camshaft Sprocket Installation
    124
  - Da Camshaft Sprocket Spacer Installation
    124
  - Timing Belt, Timing Belt B
    125
  - Aa Timing Belt B Installation
    126
  - Aa" Auto Tensioner Removal
    126
  - Ab" Timing Belt/Timing Belt B Removal
    126
  - Ba Timing Belt B Tension Adjustment
    126
  - Ca Timing Belt Installation
    127
  - Da Auto Tensioner Installation
    128
  - Ea Timing Belt Tension Adjustment
    130
  - Crankshaft Front Oil Seal
    131
  - Aa Crankshaft Front Oil Seal Installation
    132
  - Aa" Crankshaft Sprocket Removal
    132
  - Ba Crankshaft Sprocket B/Flange/Crankshaft Sprocket Installation
    132
  - Crankshaft Rear Oil Seal
    134
  - "Aa Crankshaft Rear Oil Seal Installation
    135
  - Aa" Flywheel Bolt /Drive Plate Bolt
    135
  - Ba Drive Plate Bolt /Flywheel Bolt
    135
  - Engine Assembly
    136
  - A/C Compressor Assembly Removal
    138
  - Aa Engine Assembly Installation
    138
  - Aa" Power Steering Oil Pump Assembly and
    138
  - Ab" Engine Assembly Removal
    138
- General
  141
- Outline of Change
  141
- Service Specifications
  141
- Special Tools
  141
- Compression Pressure Check
  142
- Ignition Timing Check
  142
- On-Vehicle Service
  142
- Camshaft Oil Seal
  143
- Cylinder Head Gasket
  144
- Timing Belt and Timing Belt B
  146
- Timing Belt, Timing Belt B
  146
- Crankshaft Front Oil Seal
  147
  - Crankshaft Pulley
    166
  - Camshaft and Camshaft Oil Seal
    167
  - Ac" Rocker Arm and Shaft Assembly Removal
    168
  - AA Camshaft Bearing Cap Installation
    169
  - BA Rocker Arm and Shaft Assembly Installation
    169
  - Ca Camshaft Oil Seal Installation
    169
  - Da Camshaft Sprocket Installation
    169
  - Timing Belt and Timing Belt
    175
  - Aa Oil Seal Installation
    179
  - Aa" Oil Seal Removal
    179
- Crankshaft Rear Oil Seal
  180
  - Ba Oil Separator Installation
    181
  - Ca Flywheel
    181
- Engine Assembly
  182
- General
  187
- General Information
  187
- Outline of Changes
  187
- Service Specifications
  187
- Special Tools
  187
- Idle Speed Check
  188
- Injection Timing Check and Adjustment
  188
- On-Vehicle Service
  188
- OIL PAN <4D56-Step III
  189
- CYLINDER HEAD GASKET <4D56-Step
  190
- Cylinder Head Gasket and Cylinder Head Installation
  190
- TIMING BELT and TIMING BELT B <4D56-Step III
  192
- Recommended Precautions
  196
- Lubricants
  197
- Special Tools
  197
- Engine Oil Check
  197
- Engine Oil Replacement
  197
- Oil Filter Replacement
  198
- Engine Oil Cooler
  200
- Ba Eye Bolt Installation
  201
- Aa Oil Cooler Hose Assembly
  201
- Aa" Eye Bolts Removal
  201
- Engine Oil Inspection
  210
Register Code
224
- General Information
  243
- Sealant
  246
- Service Specifications
  246
- Special Tools
  247
- Troubleshooting
  248
- Idle Position Switch and Throttle Position Sensor Adjustment
  318
- On-Vehicle Service
  318
- Throttle Body (Throttle Valve Area) Cleaning
  318
- Basic Idle Speed Adjustment
  319
- Fixed Sas Adjustment
  319
- Fuel Pressure Test
  321
- Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure)
  324
- Fuel Pump Operation Check
  324
- Component Location
  325
- Control Relay and Fuel Pump Relay Continuity Check
  326
- Engine Coolant Temperature Sensor Check
  326
- Intake Air Temperature Sensor Check
  326
- Idle Position Switch Check
  327
- Throttle Position Sensor Check
  327
- Oxygen Sensor Check
  328
- Checking the Injection Condition
  329
- Injector Check
  329
  - Measurement of Resistance between Terminals
    329
  - Checking the Coil Resistance
    330
- Idle Speed Control (ISC) Servo (Stepper Motor) Check
  330
- Purge Control Solenoid Valve Check
  331
- General
  403
- General Information
  403
- General Specifications
  403
- Outline of Changes
  403
- Self-Diagnosis Function
  403
- Service Specifications
  403
- Diagnosis Function
  404
- Special Tools
  404
- Troubleshooting
  404
- Fail-Safe Function Reference Table
  408
- Inspection Chart for Diagnosis Codes
  409
- Inspection Procedure Classified by Diagnosis Code
  410
- Inspection Chart for Trouble Symptoms
  442
- Inspection Procedure for Trouble Symptoms
  443
- Data List Reference Table
  467
- Actuator Test Reference Table
  472
- Check at the Engine-ECU Terminals
  473
- Inspection Procedure Using an Analyzer
  479
- Component Location
  483
- On-Vehicle Service
  483
- Oxygen Sensor Check
  484
  - Diesel Fuel
    487
  - Fuel Tank
    505
- General
  513
- General Information
  513
- Outline of Change
  513
- Service Specifications
  516
- Special Tools
  517
- Troubleshooting
  518
- Idle Speed Check and Adjustment
  568
- Injection Nozzle Check and Adjustment
  568
- Injection Timing Check and Adjustment
  568
- On-Vehicle Service
  568
- Accelerator Pedal Position Sensor (APS) Adjustment
  569
- Accelerator Pedal Position Sensor (APS) Check
  570
- Control Relay Continuity Check
  570
- Idle Switch Check
  570
- Boost Air Temperature Sensor
  571
- Engine Coolant Temperature Sensor Check
  571
- Temperature Sensor) Check
  571
- Evacuation of Air from Fuel Filter
  572
- Evacuation of Water from Fuel Filter
  572
- Fuel Filter Cartridge Replacement
  572
- EGR Valve Position Sensor Check
  573
- Fuel Injection Pump Check
  573
- Throttle Actuator Check
  575
- Throttle Solenoid Valve Check
  575
- EGR Control Solenoid Valve Check
  576
- Variable Geometry Solenoid Valve Check
  576
- Injection Nozzle
  577
- Injection Pump
  577
- Water Pump
  589
- General
  599
- GENERAL SPECIFICATIONS <4D56-Step III
  599
- Outline of Change
  599
- SERVICE SPECIFICATION <4D56-Step III
  599
- COOLING FAN <4D56-Step III
  600
- THERMOSTAT <4D56-Step III
  601
- WATER PUMP <4D56-Step III
  602
- WATER HOSE and WATER PIPE <4D56-Step III
  604
- RADIATOR <4D56-Step III
  605
  - Air Cleaner
    610
  - Exhaust Pipe and Main Muffler
    625
- General
  633
- Outline of Changes
  633
- Service Specifications
  633
- Special Tool <4G64
  633
- On-Vehicle Service
  634
- Turbocharger Supercharging Pressure Check
  634
- Supercharging Pressure Control System Check
  635
- Variable Geometry Actuator Check
  636
- Variable Geometry Solenoid Valve Check
  636
- AIR CLEANER <4D56-Step III
  637
- INTERCOOLER <4D56-Step III
  637
- Waste Gate Actuator Check
  637
- INTAKE and EXHAUST MANIFOLD and TURBOCHARGER <4D56-Step III
  638
- Exhaust Pipe and Main Muffler <4G64
  642
  - Charging System
    646
  - Starting System
    662
  - Glow Plug
    694
- General
  699
- General Information
  699
- Ignition System
  699
- Outline of Change
  699
- Ignition Coil Check
  700
- On-Vehicle Service
  700
- Power Transistor Continuity Check
  700
- Waveform Check Using an Analyzer
  701
- Ignition Coil and Power Transistor <4G6
  708
- Crank Angle Sensor
  709
- Camshaft Position Sensor <4G6
  710
- General
  710
- Glow System
  710
- Outline of Change
  710
- General Information
  718
- System
  718
- Vacuum Hose
  719
- Throttle Body
  720
  - Vacuum Circuit Diagram
    720
  - Crankcase Emission Control System
    721
- System Diagram
  721
- Component Location
  722
  - Purge Control System Check
    724
  - Purge Port Vacuum Check
    724
- EGR Valve Check
  727
- Exhaust Gas Recirculation (EGR) Control System Check
  727
- EGR Control Solenoid Valve Check
  728
- EGR Port Vacuum Check
  728
- Catalytic Converter
  729
- General Information
  729
- Canister and Two-Way Valve
  730
- Engine Control System <Diesel
  741
- General
  741
- Outline of Change
  741
- SEALANT <4D56-Step III
  741
- ACCELERATOR PEDAL <4D56-Step III
  742
- Emission Control
  743
- Emission Control System <Mpi
  743
- Evaporative Emission Control
  743
- General
  743
- Outline of Change
  743
- Purge Control Solenoid Valve Check
  743
- Service Specifications
  743
- System
  743
- Emission Control System <Diesel
  744
- EXHAUST GAS RECIRCULATION (EGR) SYSTEM <4D56-Step III
  744
- General
  744
- General Information
  744
- Outline of Change
  744
- Service Specification
  744
- System Diagram
  744
- Component Location
  745
- EGR Solenoid Valve Operation Check
  745
- Function Check
  745
- Accelerator Pedal Position Sensor (APS), Engine Coolant Temperature Sensor, Boost Air Temperature Sensor, Fuel Temperature Sensor, EGR Valve Position Sensor Check
  746
- Check at the Engine-ECU Terminals
  746
- EGR Solenoid Valve Resistance Check
  746
- EGR VALVE, EGR COOLER <4D56-Step III
  747
  - Clutch Pedal
    754
  - Clutch Control
    755
  - Transmission Oil Check
    760
  - Road Test
    781
  - Transmission Control
    800
  - Drive Shaft
    859
  - Axle Assembly
    918
  - Axle Shaft
    920
  - Rear Suspension Assembly
    1008
- General Information
  1011
- Configuration Diagram
  1012
- Lubricants
  1014
- Sealants
  1014
- Special Tools
  1014
- Troubleshooting
  1015
- Brake Pedal Check and Adjustment
  1018
- On-Vehicle Service
  1018
- Brake Booster Operating Test
  1019
- Stop Lamp Switch Check
  1019
- Bleeding
  1020
- Brake Booster Vacuum Switch Check <Diesel-Powered Vehicles
  1020
- Check Valve Operation Check
  1020
- Brake Fluid Level Sensor Check
  1021
- Load Sensing Spring Length Check and Adjustment
  1021
- Front Disc Brake Rotor Check
  1024
- Brake Lining Thickness Check
  1025
- Brake Drum Inside Diameter Check
  1026
- Brake Lining and Brake Drum Connection Check
  1026
- Brake Pedal
  1027
- Booster
  1049
- Load Sensing Proportioning Valve Function Test
  1049
- Master Cylinder and Brake
  1049
- Load Sensing Proportioning
  1070
- Valve
  1070
- Front Disc Brake
  1079
- Rear Drum Brake
  1130
  - Parking Brake Cable
    1167
  - Power Steering Oil Pump
    1206
  - Steering Linkage
    1218
  - Rear Body
    1257
  - Fuel Filler Door
    1261
  - Window Glass
    1264
  - Window Repair
    1264
  - Rear Window Glass
    1269
- Door Assembly
  1284
- Door Trim and Waterproof Film
  1286
- Door Glass and Regulator
  1288
- Door Handle and Latch
  1292
- Window Glass Runchannel and Door Opening Weatherstrip
  1295
- Rear Gate
  1296
- Rear Gate Outside Handle Play Check and Adjustment
  1296
- Service Specification
  1296
Vehicle Line
1303
- Windshield Wiper and Washer
  1327
- Door Mirror
  1335
- Radiator Grille
  1348
- Instrument Panel
  1357
- Rear Seat
  1370
- Rear Seat Belt
  1372
Body Type
1382
- Battery Testing Procedure
  1517
- Communication with All Systems Is Impossible
  1519
- Fuel Gauge Unit Check
  1540
- Rear Combination Lamp
  1564
- Cigarette Lighter
  1570
- Rear Window Defogger
  1594
- Rear Window Defogger Switch
  1595
Engine Type
1618
Model Year
1637
- Refrigerant Line
  1672
- Heater Unit
  1716

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