engine MITSUBISHI L200 2015 (in English) Service Manual

NOTElIt is recommended to start the vehicle with
parking brake partially, but not completely,applied by slightly pulling the parking brake
lever.
After the vehicle has become free, do not forget to release the parking brake.
l If it is necessary to drive in extremely mud-
dy conditions, the use of tyre chains is rec-
ommended. Because the extent of muddy conditions is difficult to judge and the vehi- cle could become bogged down very deeply,
operation should be at a low speed. If possi-
ble, get out of the vehicle and check the con- ditions ahead before proceeding.
l Driving over roads in coastal areas or roads
on which anti-skid preparations have been spread can cause rust on the vehicle; wash
the vehicle thoroughly as soon as possible
after such use.
Climbing sharp grades
Set the transfer shift lever to “4L” position
(easy select 4WD), “4LLc” position (super
select 4WD) to maximize the engine torque.
WARNINGl Go straight up. Do not try to traverse
across a steep slope.WARNINGl If you begin to lose traction, ease off the
accelerator pedal and gently turn the
steering wheel alternatively left and right to regain adequate traction again.NOTEl Choose as smooth a slope as possible with
few stones or other obstacles.
l Before attempting to drive up the slope,
walk up it to confirm that the vehicle canhandle the grade.
Descending sharp grades
Set the transfer shift lever to “4L” position
(easy select 4WD), “4LLc” position (super
select 4WD), use the engine brake (down- shifting) and descend slowly.
WARNINGl Avoid snaking down a sharp grade. De-
scend the grade as straight as possible.NOTEl When descending a sharp grade, if the
brakes are applied suddenly because of an
obstacle encountered, control of the vehicle
could be lost. Before descending the slope,
walk down it and confirm the path.NOTEl Before descending a grade, it is necessary to
choose the appropriate gear. Avoid changing
gears or depressing the clutch while de-
scending the grade.
l MITSUBISHI
MOTORS is not responsible
to the operator for any damage or injury caused or liability incurred by improper and
negligent operation of a vehicle. All techni- ques of vehicle operation described herein depend on the skill and experience of the op- erator and other participating parties and any
deviation from the recommended operation
instructions above is at their own risk.
Turning sharp corners
When turning a sharp corner in “4H” or “4L”
position (easy select 4WD), “4HLc” or “4LLc” position (super select 4WD) at low speed, a slight difference in steering may be
experienced similar to as if the brakes were applied. This is called tight corner braking and results from each of the 4 tyres being at a
different distance from the corner.
The phenomenon is peculiar to 4-wheel drive vehicles. If this occurs, either straighten the steering wheel, or change to rear-wheel drive.
4-wheel drive operation
6-40OKTE15E3Starting and driving6

Crossing a stream
4-wheel drive vehicles are not necessarilywaterproof. If the electrical circuits become
wet, further operation of the vehicle will be impossible; therefore, avoid crossing streams
unless absolutely necessary. If crossing a stream is unavoidable, use the following pro-
cedure: 1. Check depths of a stream and geographi-
cal features before attempting to cross a stream and ford the stream where the
water is as shallow as practicable.
2. Set the transfer shift lever to “4L” posi-
tion (easy select 4WD), “4LLc” position (super select 4WD).
3. Drive slowly at a speed of approximate-
ly 5 km/h (3 mph) to avoid splashing too
much water.
CAUTIONl Never cross a stream where the water is
deep.
Do not change gears while crossing the stream.
Frequent crossing of streams can adversely
affect the life span of the vehicle; we recom- mend you to take the necessary measures toprepare, inspect, and repair the vehicle.After crossing a stream, apply the brakes to
be sure they are functioning properly. If the
brakes are wet and not functioning properly,
dry them out by driving slowly while lightly depressing the brake pedal.
Inspect each part of the vehicle carefully.Inspection and maintenance
following rough roadoperation E00606700048
After operating the vehicle in rough road
conditions, be sure to perform the following inspection and maintenance procedures:
l Check that the vehicle has not been dam-
aged by rocks, gravel, etc.
l Carefully wash the vehicle with water.
After washing, drive the vehicle slowly
while lightly depressing the brake pedal in order to dry out the brakes. If the brakes still do not function properly, we
recommend you to have the brakes
checked as soon as possible.
l Remove the insects, dried grass, etc.
clogging the radiator core.
l After crossing a stream, be sure to have
the following items inspected at a
MITSUBISHI MOTORS Authorized
Service Point and take the necessary
measures.
• Check the brake system and, if neces-
sary, have it serviced.
• Check the engine, transmission, trans-
fer, and differential oil or grease level
and turbidity. If the oil or grease is
milky, it indicates water contamina-
tion. Replace it with new oil or grease.
• Grease the propeller shaft.
• Check the inside of the vehicle. If in-
gress of water is found, dry the carpetetc.
• Inspect the headlamps. If the head-
lamp bulb is flooded with water, we
recommend you to have it drained.Cautions on handling of 4-
wheel drive vehicles E00606800368
Tyres and wheels
Since the driving torque can be applied to the
4 wheels, the performance of the vehicle when operating in 4-wheel drive is greatly af- fected by the condition of the tyres.

Pay close attention to the tyres.
l Install specified tyres on all wheels. Re-
fer to “Tyres and wheels” on page
11-19.
Inspection and maintenance following rough road operation
6-41OKTE15E3Starting and driving6

lBe sure to fit all 4 tyres and wheels of
the same size and type.
When replacement of any of the tyres or wheels is necessary, replace all of them.
l All tyres should be rotated whenever the
wear difference between the front and rear tyres is recognizable.
Good vehicle performance cannot be expec- ted if there is a difference in wear between
tyres. Refer to “Tyre rotation” on page 10-14.
l Check the tyre inflation pressure regular-
ly.CAUTIONl Always use tyres of the same size, same
type, and same brand, and which have no wear differences. Using tyres of different
size, type, brands or degree of wear, will in- crease the differential oil temperature, result-
ing in possible damage to the driving sys-
tem. Further, the drive train will be subjec-
ted to excessive loading, possibly leading to oil leakage, component seizure, or other seri-
ous faults.
Towing
If towing is necessary, we recommend you to
have it done by your MITSUBISHI
MOTORS Authorized Service Point or a
commercial tow truck service.
In the following cases, transport the vehicle
using a tow truck.
l The engine runs but the vehicle does not
move or abnormal noise is produced.
l Inspection of the vehicle’s underside re-
veals that oil or some other fluid is leak- ing.Only when you cannot receive a towing serv-ice from a MITSUBISHI MOTORS Author-
ized Service Point or commercial tow truck
service, tow your vehicle carefully in accord- ance with the instructions given in “Towing”
on page 8-22 .
Cautions on handling of 4-wheel drive vehicles
6-42OKTE15E3Starting and driving6

CAUTIONlBe sure to shift the transfer shift lever to
“2H” position and transport the vehicle with the driving wheels on a carriage (Type A, C
or D) as illustrated.
Never try to tow with the transfer shift lever
in “4H” or “4L” position (easy select 4WD), “4H”, “4HLc” or “4LLc” position (super se-
lect 4WD) and with the front or rear wheels
on the ground (Type A or B) as illustrated. This could result in damage to the drivetrain,
or unstable towing.
If you cannot shift the transfer shift lever to “2H” position or the transmission is mal-
functioning or damaged, transport the vehi- cle with all the wheels on a carriage (Type C
or D) as illustrated.
Jacking up a 4-wheel drive ve-
hicle
WARNINGl Do not crank the engine while jacking up
the vehicle.
The tyre on the ground may turn and the
vehicle may roll off the jack.
Clutch operation
Quick or slight clutch engagement made
while the engine is running at high speed will
cause damage to the clutch and transmission because the tractive force is very great.
Operate the pedal slowly and positively.Limited-slip differential*
E00606900037
A limited-slip differential is applied for therear wheel differential only. The features of
this limited-slip differential are described be- low:

Just as with a conventional differential, the wheel on one side is allowed to turn at a dif-
ferent speed from the wheel on the other side
when the vehicle is cornering. The difference between the limited-slip differential and aconventional differential is that if the wheelon one side of the vehicle loses traction, a greater amount of torque is applied to the wheel on the other side to improve traction.
NOTEl Even if there is a difference in the amount of
traction the wheels can get, if both of them
are spinning, the limited-slip differential will not be effective.CAUTIONl Never start the engine while one of the rear
wheels is jacked up and the other in contact
with the ground; doing so may cause the ve- hicle to jump forward.
l When attempting to extract the vehicle from
snow, mud, etc., and the engine is run con-
tinuously at high speed, the limited-slip dif- ferential will be adversely affected.Braking
E00607001928
All the parts of the brake system are critical
to safety. We recommend you to have the ve- hicle checked at regular intervals according
to the service booklet.
CAUTIONl Avoid driving habits that cause heavy brak-
ing and never “ride” the brakes by resting
your foot on the brake pedal while driving.
It causes brake overheating and fade.
Limited-slip differential*
6-43OKTE15E3Starting and driving6

Brake system
The service brake is divided into two brake
circuits. And your vehicle is equipped with
power brakes. If one brake circuit fails, the
other is available to stop the vehicle. If you should lose the power assist for some reason, the brakes will still work. In these situations,
even if the brake pedal moves down to the
very end of its possible stroke or resists being
depressed, keep depressing the brake pedal down harder and further than usual; stop
driving as soon as possible and have the
brake system repaired.
WARNINGl Do not turn off the engine while your ve-
hicle is in motion. If you turn off the en-
gine while driving, the power assistance for the braking system will stop working
and your brakes will not work effectively.
l If the power assist is lost or if either brake
hydraulic system stops working properly, have your vehicle checked immediately.
Warning lamp
The brake warning lamp illuminates to indi-
cate a fault in the braking system. Refer to “Brake warning lamp” on page 5-08.
When brakes are wet
Check the brake system while driving at a
low speed immediately after starting, espe- cially when the brakes are wet, to confirmthey work normally.
A film of water can be formed on the brake
discs or brake drums and prevent normal braking after driving in heavy rain or through
large puddles, or after the vehicle is washed.
If this occurs, dry the brakes out by driving
slowly while lightly depressing the brake pedal.
When driving downhill
It is important to take advantage of the en- gine braking by shifting to a lower shift posi-tion while driving on steep downhill roads in
order to prevent the brakes from overheating.
WARNINGl Do not leave any objects near the brake
pedal or let a floor mat slide under it; do-
ing so could prevent the full pedal stroke that would be necessary in an emergency.Make sure that the pedal can be operatedfreely at all times. Make sure the floor
mat is securely held in place.Brake pads and linings
l Avoid hard braking situations.
New brakes need to be broken-in by
moderate use for the first 200 km (124 miles).
l The disc brakes are provided with a
warning device which emits a shrieking
metallic sound while braking if the brake pads have reached their wear limit.
If you hear this sound, have the brake pads replaced.
WARNINGl Driving with worn brake pads will make
it harder to stop, and can cause an acci-
dent.Brake assist system*
E00627000392
The brake assist system is a device assistingdrivers who cannot depress the brake pedalfirmly when it is necessary to do so (such as
in emergency stop situations) and provides
greater braking force.
If the brake pedal is depressed suddenly, the brakes will be applied with more force thanusual.
Brake assist system*
6-44OKTE15E3Starting and driving6

If the warning lamp illuminateswhile driving
E00607302436
If only the ABS warning lamp illuminates
l Avoid hard braking and high-speed driv-
ing. Stop the vehicle in a safe place.
Restart the engine and check to see whether the lamp goes out after a few
minutes driving; if it then remains off during driving, there is no problem.
However, if the lamp does not go out, or if it lights up again when the vehicle is
driven, we recommend you to have the
vehicle checked as soon as possible.
l The ABS warning lamp can illuminate if
the battery voltage is insufficient when the engine is started. In this case, it doesnot indicate an ABS fault.
Charge the battery by allowing the en- gine to idle for a while.
If the battery has been charged but the
ABS warning lamp continues to illumi-
nate or illuminates intermittently, have
the vehicle inspected.
If the ABS warning lamp and
brake warning lamp illuminate
at the same time
The ABS and brake force distribution func- tion will not work, so hard braking could
make the vehicle unstable.
Avoid hard braking and high-speed driving.
Stop the vehicle in a safe place and contact a MITSUBISHI MOTORS Authorized Service
Point.
NOTEl Immediately after the vehicle starts moving
after engine start up, a whining sound of a motor will be heard from the engine com-
partment. If the brake pedal is depressed at that moment, you can feel the brake pedal
pulsating.
This pulsation is due to the self-diagnosis
operation of the ABS and does not indicate a malfunction.
l After driving on snowy roads, remove any
snow and ice which may have become ad-
hered to the wheel areas.
When doing this, be careful not to damage the wheel speed sensors (A) and cables loca-NOTEted at each wheel on vehicles equipped with
an ABS.
l The ABS becomes operative after the vehi-
cle has accelerated to a speed in excess of approximately 10 km/h (6 mph). It stops op-
erating when the vehicle decelerates to a speed below approximately 7 km/h (4 mph).
Anti-lock brake system (ABS)*
6-47OKTE15E3Starting and driving6 Front Rear

Power steering systemE00607400387
The power steering system operates while the
engine is running. It helps reduce the effort needed to turn the steering wheel.
The power steering system has mechanical
steering capability in case the power assist is lost. If the power assist is lost for some rea-
son, you will still be able to steer your vehi-
cle, but you will notice it takes much more effort to steer. If this happens, have your ve-
hicle inspected at an authorized MITSUBISHI MOTORS service point.WARNINGl Do not stop the engine while the vehicle is
moving. Stopping the engine would make
the steering wheel extremely hard to turn, possibly resulting in an accident.CAUTIONl Do not leave the steering wheel turned all
the way in one direction. This can causedamage to the power steering system.Active Stability & Traction
Control (ASTC)* E00616700344
The active stability & traction control (ASTC) takes overall control of the anti-lockbrake system, traction control function and Active Stability Control function to help
maintain the vehicle’s control and traction. Please read this section in conjunction with the page on the anti-lock brake system, trac- tion control function and Active Stability
Control function.

Anti-lock brake system (ABS) ® p. 6-45
Active Traction Control function ® p. 6-49
Active Stability Control function ® p. 6-49CAUTIONl Do not over-rely on the ASTC. This system,
like any other system, has limits and cannot
help you to maintain traction and control of
the vehicle in all circumstances. Reckless
driving may lead to accidents. Always drive carefully, taking into account the traffic,road and environmental conditions.
l Be sure to use the same specified type and
size of tyre on all 4 wheels. Otherwise, the
ASTC may not work correctly.NOTEl After your vehicle is driven a short distance
after starting the engine, a click is heard from the engine compartment; however, this
is only the sound of ASTC being checked.
l Some vibration will be felt in the vehicle
body and a whining sound of a motor will be heard from the engine compartment when the ASTC functions. This is a normal result
of the ASTC operation, and does not indi- cate a malfunction.
l The ASTC does not operate while the ABS
warning lamp is illuminated.
l On vehicles with the rear differential lock,
the ASTC and ABS functions are suspended
while the rear differential lock is activated. ASTC indication lamp, ASTC OFF indica-tion lamp and ABS warning lamp are illumi-
nated while these functions are suspended. It
does not indicate a problem. When the rear differential lock is disengaged, these lamps
go out and function again.
Refer to “ABS warning lamp” on page 6-46,
“ASTC indication lamp, ASTC OFF indica-
tion lamp” on page 6-49.
Power steering system
6-48OKTE15E3Starting and driving6

Driving hints
E00616800039
When extricating the vehicle from mud, sand
or fresh snow, you may find that operation of
the ASTC prevents the engine speed from in-
creasing in response to depression of the ac- celerator pedal. If this happens and the vehi-cle remains stuck as a result, deactivate the
ASC function by pressing the “ASC OFF”
switch. The vehicle will then be easier to ex- tricate. (Brake control of the ATC function isstill working to prevent wheel spins when the
ASC function is deactivated by pressing the “ASC OFF” switch.)
Active Stability Control func-
tion
E00616900115
The Active Stability Control function is de- signed to improve the vehicle’s stability byrestraining its tendency to slip sideways (for
example, when rounding a curve in slippery conditions, or when the driver takes rapid
steering action to avoid an obstacle). It works
by controlling the engine output and brake on each wheel.
NOTEl On vehicles with rear differential locks, the
Active Stability Control function does notoperate when the rear differential lock is ac-
tivated.
“ASC OFF” switch
The Active Stability Control function is auto-
matically activated when the ignition switch
is turned to the “ON” position. You can deac- tivate the system by pressing the “ASC OFF”
switch when the vehicle speed is below 40 km/h (25 mph). To reactivate the Active
Stability Control function, press the ASC OFF switch again. It is strongly recommen-
ded that the Active Stability Control function
normally be kept activated.
Type 1Type 2
NOTEl If the vehicle speed increases to about
120 km/h (74 mph) with the Active Stability Control function deactivated, the Active Sta-bility Control function automatically starts operating. To subsequently stop the Active
Stability Control function, stop the vehicle
and press the ASC OFF switch again.Active Traction Control func-
tion
E00617000025
On slippery surfaces, active traction control function prevents the drive wheels from ex- cessive spinning, thus helping the vehicle to
start moving from a stop. It also provides suf-
ficient driving force and steering perform- ance as the vehicle turns at accelerated
speeds.
CAUTIONl When driving a vehicle on a snowy or icy
road, be sure to install snow tyres and drive the vehicle at moderate speeds.ASTC indication lamp, ASTC
OFF indication lamp
E00617100114
The Active Stability Control function and ac-
tive traction control function share the same indication lamp.
Active Stability & Traction Control (ASTC)*
6-49OKTE15E3Starting and driving6

The indication lamps should illuminate when
the ignition switch is turned to the “ON” po- sition and should go off after a few seconds.
If the indication lamps stay on or do not illu- minate when the ignition switch is turned to
the “ON” position, we recommend you to have your vehicle inspected as soon as possi-ble.
indication lamp blinks when the Active
Stability Control function or active traction
control function is operating.
indication lamp is illuminated when the
Active Stability Control function is OFF.
CAUTIONl When indication lamp blinks, Active Sta-
bility Control function or active traction con- trol function is operating, which means that
the road is slippery or that your vehicle’s wheels are slipping excessively. If this hap-
pens, drive slower with less accelerator in-
put.CAUTIONl If an abnormal condition occurs in the sys-
tem while driving, the indication lamp
will illuminate.
In these cases, follow these procedures:
• If the temperature in the braking system
continues to increase due to continuous brake control on a slippery road surface,
the
indication lamp will illuminate, and
operation of the Active Stability Control function and active traction control func-
tion will be suspended to protect the brake
system. (Normal operation of the vehicle will not be affected.) Park your vehicle in
a safe place. When the temperature in the
braking system has come down, the
in-
dication lamp will go off and the Active
Stability Control function and active trac- tion control function will start operating again.
• If the
indication lamp does not go out
even though the above procedure is fol-
lowed, there could be a problem in the system.
Stop the engine and start the engine again
and check whether the
indication lamp
goes out. If the indication lamp goes out, there is no abnormal condition.
If the
indication lamp illuminates even
after your vehicle is driven a short dis-
tance after restarting the engine, we rec-
ommend you to have your vehicle checked as soon as possible.
CAUTIONl If the vehicle is towed with the ignition
switch in the “ON” position and only the
front wheels or only the rear wheels raised off the ground, the ASTC may operate, re-
sulting in an accident. When towing the ve- hicle with the front wheels raised, keep the
ignition switch in the “LOCK” or “ACC” position. When towing the vehicle with the
rear wheels raised, keep the ignition switch in the “ACC” position.
Refer to “Towing” on page 8-22.Cruise control*
E00609100779
Cruise control is an automatic speed controlsystem that keeps a set speed. It can be acti-vated at about 40 km/h (25 mph) or more.
Cruise control*
6-50OKTE15E3Starting and driving6

CAUTIONlWhen you do not wish to drive at a set
speed, turn off the cruise control for safety.
l Do not use cruise control when driving con-
ditions will not allow you to stay at the same
speed, such as in heavy traffic or on roads that are winding, icy, snow-covered, wet,
slippery, on a steep downhill slope.
l On vehicles with manual transmission, do
not move the gearshift lever to the “N” (Neutral) position while driving at a setspeed without depressing the clutch pedal.The engine will run too fast and might be damaged.NOTEl Cruise control may not be able to keep your
speed on uphills or downhills.
l Your speed may decrease on a steep uphill.
You may use the accelerator pedal if you
want to stay at your set speed.
l Your speed may increase to more than the
set speed on a steep downhill. You must use the brake to control your speed. As a result, the set speed driving is deactivated.Cruise control switches
E00624100103
A- “ON OFF” switch
Used to turn on and off the cruise control.
B- “COAST SET” switch
Used to reduce the set speed and to set the
desired speed.

C- “ACC RES” switch
Used to increase the set speed and to return to
the original set speed.

D- “CANCEL” switch
Used to deactivate the set speed driving.
NOTEl When operating the cruise control switches,
press the cruise control switches correctly.
The set speed driving may be deactivated automatically if two or more switches of the
cruise control are pressed at the same time.To activate
E00609300771
1. With the ignition switch in the “ON” po-
sition, press the “ON OFF” switch (A) to turn on the cruise control. The
“CRUISE” indication lamp in the meter cluster will come on.
Cruise control*
6-51OKTE15E3Starting and driving6