engine MITSUBISHI L200 2004 (in English) Repair Manual

FOR EMERGENCIES
NOTE
Take care when lowering the vehicle, as
sudden closure of the jack release valve
can cause damage to the jack.
3. Remove the jack.
NOTE
When the jack is difficult to remove by
hand, insert the jack handle into the holder
and hook the jack handle notch onto the
holder notch and secure it there. Then pull
the jack handle and remove the jack.
4. Press the piston down all the way,
and turn the release valve clockwise
as far as possible.
5. Store the jack and jack handle.
WARNING(1) Raise the vehicle so the tyre just
clears the ground. It is danger-
ous to raise the vehicle any
higher.
(2) Never get under the vehicle
while using the jack. Avoid jar-
ring the raised vehicle or leaving
it supported on the jack for any
longer than required. Both are
very dangerous.
(3) Do not start or run the engine
while the vehicle is on the jack.
The vehicle might start moving
and cause the vehicle to fall
down from the jack.
(4) Do not turn the jacked up
wheels. The tyres remaining on
the ground may turn, causing
the vehicle body to fall down
from the jack.
(5) No one should stay in the vehi-
cle while the jack is used.
(6) On vehicles with limited slip
differential, jack up the rear
wheel and keep it from turning.
If the raised wheel turns, the
wheel on the ground will roll the
vehicle off the jack.
CAUTIONUse only the jack supplied with the
vehicle and use it only for changing
wheels.
Spare wheelEN03APDd
The spare wheel is stored under the floor
of the cargo bed.
CAUTION(1) When removing the spare wheel,
it is recommended you wear
gloves. Removing the spare
wheel with your hands may
cause injury to the fingers.
(2) Check the air pressure in the
spare wheel weekly, making
sure it is ready for emergency
use at any time.
Driving with an insufficient tyre
pressure can lead to an acci-
dent. If you have no choice but
to drive with an insufficient tyre
pressure, keep your speed down
and inflate the tyre to the correct
pressure as soon as possible.
(Refer to “Tyre inflation pres-
sure” on page 9-11.)
Maintaining the spare wheel at
the highest specified air pres-
sure will ensure that it can al-
ways be used under any condi-
tions (city/high-speed driving,
varying load weight, etc.).
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FOR EMERGENCIES
(4) Be sure the towing speed is within the
legal limit. In addition, if the vehicle is
equipped with an automatic transmis-
sion, make sure that the towing speed
and distance given below are never
exceeded.
Towing speed: 50 km/h
Towing distance: 50 km
(5) If the transmission is malfunctioning
or damaged, or if the vehicle is
equipped with an automatic transmis-
sion must be towed farther than
50 km, tow the vehicle by a tow truck.
(6) Turn the ignition switch to the “ACC”
or “ON” position to unlock the steering
wheel.
CAUTION(1) As the engine is not running, the
brake booster and power steer-
ing pump do not operate. This
means higher brake depression
force and higher steering effort
are required. Therefore, vehicle
operation is more difficult than
usual.
(2) Do not leave the key in the
“LOCK” position. If the key is re-
moved while driving, the steer-
ing will be locked causing loss
of control.
(7) Turn on the hazard warning lamps.
(8) During towing make sure that close
contact is maintained between the dri-
vers of both vehicles, and that the ve-
hicles travel at low speed. Avoid
abrupt starting or stopping.
WARNINGAvoid sudden braking, sudden ac-
celeration and sharp turning; such
operation could cause damage to
the towing hooks or the tow rope.
People in the vicinity could be in-
jured as a result.
CAUTIONWhen going down a long slope, the
brakes may overheat, reducing ef-
fectiveness. Have your vehicle
towed on a trailer.
(9) Towing should only be done by a pro-
fessional tow service if it will involve
towing on winding roads, hills or in
heavy traffic. If you have any doubts,
use a professional tow service.
(10) When the towing hooks are used, be
very careful so that the rope may not
cause damage to the body.
CAUTIONTo prevent entry of exhaust gas from
the towing vehicle, set the air selec-
tion lever to the recirculation posi-
tion.
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FOR EMERGENCIES
If your vehicle tows another vehicle
The spring shackles are located as shown
in the illustration. Attach the tow rope to
the spring shackles (4-wheel drive models
only).Engine overheatingEN26AABc
If the water temperature gauge indication
remains in the overheating zone for a long
time, the engine may be overheating. If
this occurs, take the following corrective
measures:
1. Stop the vehicle in a safe place.
CAUTION(1) Towing another vehicle using
the shackles to attach the tow-
ing rope is only possible on 4-
wheel drive models. On 2-wheel
drive models, this method will
cause bumper deformation.
(2) 2-wheel drive models can only
tow other vehicles when fitted
with a tow bar. When using the
tow bar, ensure that the rope is
securely fitted and that the
weight of the vehicle to be towed
does not exceed the maximum
allowed trailer weight listed on
the tow bar.
NOTE
Your vehicle should only be used to tow
another vehicle if the weight of the other
vehicle is less than your vehicle.
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N25A104
BB
Rear (4WD vehicles)
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FOR EMERGENCIES
2. With the engine still running, raise the
bonnet to ventilate the engine com-
partment.
A - Radiator fan
B - Radiator cap
C - Reserve tank
NOTE
Confirm that the radiator fan is turning. If
the fan is not turning, stop the engine im-
mediately and contact an authorized
MITSUBISHI dealer for assistance.
WARNING
(1) Remember that under the bon-
net, there can be boiling water
gushing out or the support bar
could be burning hot. If the
bonnet is opened suddenly, you
could get burnt.
(2) Be careful of hot steam which
could be blowing off the reserve
tank cap.
(3) Do not attempt to remove the
radiator cap while the engine is
hot.
3. After the engine coolant temperature
has dropped to the normal tempera-
ture, stop the engine.
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ABC
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FOR EMERGENCIES
4. Check the coolant level in the reserve
tank. If there is none, make sure that
the engine has cooled down before
removing the radiator cap, because
hot steam or boiling water otherwise
will gush from the filler port and may
scald you.
5. Add coolant to the radiator and/or
reserve tank if necessary (refer to the
“Maintenance” section).
CAUTIONAdding cold water rapidly when the
engine is hot could cause the cylin-
der head and/or block to crack, add
the water a little at a time while run-
ning the engine.
Bleeding the fuel system
(diesel-powered vehicles
only)
EN07A-La
The fuel system should be bled to remove
air as described below if the fuel supply is
exhausted during travel.
1. Loosen the air plug (A) at the top of
the fuel filter. 6. Examine the radiator hoses for
coolant leakage and the fan belts for
looseness or damage.
If there is anything wrong with the
cooling system or fan belt, have the
problem corrected at an authorized
MITSUBISHI dealer.
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M36A003N07A007
A
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FOR EMERGENCIES
2. Operate the hand pump (B) slowly 6
or 7 times in order to force the water
out through the drain plug (A).
3. Tighten the drain plug (A) when water
no longer comes out.
4. Loosen the air plug and bleed the air.
(Refer to “Bleeding the fuel system.”)
5. Check to be sure that the warning
lamp illuminates when the ignition key
is turned to “ON”, and that it goes off
when the engine is started. If in doubt,
consult your nearest authorized
MITSUBISHI dealer.
Emergency startingEN28A-Te
If the engine cannot be started because
the battery is weak or dead, the battery
from another vehicle can be used with
jumper cables to start the engine.
WARNINGTo start the engine by use of jumper
cables from another vehicle, per-
form the correct procedures accord-
ing to the instruction manual. Incor-
rect procedures could result in a fire
or explosion or damage to the vehi-
cles.
1. Get the vehicles close enough so the
jumper cables can reach, but be sure
the vehicles aren’t touching each
other. If they are, it could cause a
ground connection you don’t want.
The vehicle will not start, and the bad
grounding could damage the electri-
cal systems.
CAUTIONCheck the other vehicle. It must have
a 12-volt battery.
If the other system isn’t 12-volt,
shorting can damage both vehicles.
CAUTION(1) Do not smoke or have any other
open flame near the vehicle
while bleeding the fuel system.
(2) Be sure to carefully clean away
any water drained out because
any fuel mixed with the water
could ignite and cause a fire.
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B
A
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2. You could be injured if the vehicles
roll. Set the parking brake firmly on
each vehicle. Put an automatic trans-
mission in “P” (PARK) position or a
manual transmission in “N” (Neutral)
position. Turn off the ignition switch.
WARNINGTurn off the ignition on both vehicles
beforehand. Use care to make sure
that the cables or your clothes do
not get caught by the fan or drive
belt. Personal injury could result.
NOTE
Turn off all lamps, heater and other elec-
trical loads. This will avoid sparks and help
save both batteries.
3. Make sure that the battery electrolyte
is at the proper level. Refer to “Bat-
tery” on page 9-6.
WARNINGIf the electrolyte fluid is not visible,
or appears to be frozen, Do Not At-
tempt Jump Starting!
A battery might rupture or explode if
the temperature is below the freez-
ing point or if it is not filled to the
proper level.
4. Connect one end of one jumper cable
to the positive (+) terminal of the
discharged battery, and the other end
to the positive (+) terminal of the
booster battery.
5. Connect one end of the other jumper
cable to the negative (–) terminal of
the booster battery and the other end
to the engine block of the vehicle with
the discharged battery at the point far-
thest from the battery.
NOTE
Remove the cover before connecting the
booster cable to the positive terminal of
the battery.
FOR EMERGENCIES
Type 1 -Diesel-powered vehicles with
turbo charger
Type 2 - Diesel-powered vehicles
Type 3 - Petrol-powered vehicles
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N28A041


  
Type 1
N28A031
Type 2
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FOR EMERGENCIES
WARNING(1) Be sure to observe the connect-
ing sequence of ➀ → ➁ → ➂ → ➃.
(2) Make sure that the connection ➃
is made to the engine proper. If
the connection is made directly
to the negative side of the bat-
tery, the inflammable gases gen-
erated from the battery might
catch fire and explode.
(3) When connecting the jumper ca-
ble, do not connect the positive
(+) cable to the negative (–) ter-
minal. Otherwise sparks might
cause explosion of the battery.
WARNING(1) Charging the battery while it is
installed in the vehicle might
cause the battery to catch fire
and explode. Or damage to the
vehicle could result. If it has to
be charged in that condition for
unavoidable reasons, discon-
nect the vehicle negative (–) ter-
minal connected to the battery.
(2) Keep sparks, cigarettes and
flames away from the battery be-
cause the battery may produce
an explosion.
(3) Use adequate ventilation when
charging or using the battery in
an enclosed space.
(4) Remove all the caps before
charging the battery.
(5) Electrolyte is corrosive diluted
sulphuric acid.
If electrolyte (battery acid)
comes into contact with your
hands, eyes, clothes, etc. or the
painted surface of you vehicle, it
should be thoroughly flushed
with water. If electrolyte gets in
your eyes, flush them with water
immediately and thoroughly,
and get prompt medical atten-
tion.CAUTION(1) Use care not to get the jumper
cable caught in the cooling fan
or other rotating parts in the en-
gine compartment.
(2) Use the proper cables suitable
for the battery size.
Otherwise heat damage to the
cables could result.
(3) Check the jumper cables for
damage and corrosion before
use.
6. Start the engine in the vehicle which
has the booster battery, let the engine
idle a few minutes, then start the en-
gine in the vehicle with the discharged
battery.
CAUTIONKeep the engine of the vehicle giving
assistance running.
7. After the engine is started, disconnect
the cables in the reverse order.
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N28A045




Type 3
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FOR EMERGENCIES
CAUTION(1) Do not attempt to start the en-
gine by pulling or pushing the
vehicle.
It could damage your vehicle.
(2) Always wear protective eye gog-
gles when working near the
battery.
(3) Keep the battery out of the reach
of children.
NOTE
On vehicles with the anti-lock brake
system, if the vehicle is started in motion
without fully charging the battery, irregular
rotation of the engine might cause the
anti-lock brake warning lamp to illuminate.
Refer to “Anti-lock brake system (ABS)”
on page 5-33.
What to do if the engine
speed becomes unstable
after the battery is
replaced
EN38B-G
If the engine speed becomes unstable af-
ter the battery is replaced, reset the en-
gine using the following method:
1. Stop the vehicle in a safe place.
2. Place the gearshift lever (manual
transmission) in the “N” (Neutral) po-
sition or the selector lever (automatic
transmission) in the “P” (PARK) posi-
tion.
Stop the engine.
3. Restart the engine.
4. Turn off the heater/air conditioning.
5. Allow the engine to warm up until the
needle in the water temperature
gauge stabilizes near the centre of
the gauge.
6. Stop and restart the engine.
7. Allow the engine to idle for approxi-
mately 10 minutes.
8. When the engine speed stabilizes,
the resetting procedure is complete.
NOTE
If the engine speed remains unstable after
the resetting procedure has been per-
formed, have the vehicle inspected by an
authorized MITSUBISHI dealer.
FusesEN09A-Na
Fuse block
To prevent damage to the electric system
due to short-circuiting or overloading,
each individual circuit is provided with a
fuse.
There are fuse boxes in the passenger
compartment and in the engine compart-
ment.
The fuse box in the passenger compart-
ment is located in front of the driver’s seat
as shown in the illustration.
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FOR EMERGENCIES
In the engine compartment, the fuse box
is located as shown in the illustration.Passenger compartment
The spare fuses are mounted on the fuse
box cover. Always use a fuse of the same
capacity for replacement.
Fuse load capacityEN29BPDc
The fuse box cover lists the names of the
electrical systems and the fuse capacities.
8-31
NoElectrical systemCapacity
1Rear window demister20A
2Heater20A
3Turn-signal lamps10A
4Radio10A
5——
6Electric door locks15A
Symbol
—
N29B143
1
2
3
4567
8
9
101112
13
14
15 16
17
N29B144N09A033
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