Mitsubishi L200. Manual — part 544

AC501256

A

B

C

E

E

G

A

B

C

D

F

G

A

B

C

D

D

F

F

G

E

AG

1

1

1

6

6

6

2

2

2

7

7

7

3

3

3

4

4

4

5

5

5

8

8

9

9

10

10

10

11

11

47 ± 7 N·m

47 ± 7 N·m

47 ± 7 N·m

45 ± 5 N·m

45 ± 5 N·m

63 ± 7 N·m

<Double cab>

N

N

N

N

N

Cab body mounting removal steps

1. Cab body mounting nut
2. Cab body mounting washer
3. Cab body mounting cushion
4. Cab body mounting spacer
5. Cab body mounting cushion
6. Cab body mounting washer

7. Cab body mounting bolt

<<A>>

•

Cab body

BODY MOUNTING

BODY

42-236

Rear body mounting removal
steps

8. Rear body mounting nut
9. Rear body mounting screw or bolt
10. Rear body mounting shim

Cab body mounting removal steps

REAR GATE

BODY

42-237

REMOVAL SERVICE POINTS

<<A>> CAB BODY REMOVAL
1. Remove or disconnect the following parts:

• Hood

• Radiator grille

• Headlamp

• Front bumper assembly

• Oil cooler hose <Vehicles with oil cooler>

• Radiator assembly

• Air cleaner duct

• Steering shaft joint

• Heater hose

• Power steering reservoir tank

• Brake booster vacuum hose

• Accelerator cable

• Fuel hose

• Brake pipe

• A/C piping

• Clutch release cylinder <Vehicles with manual

transmission>

• Speedometer cable

• Parking brake cable

• Shift lever knob <Vehicles with manual transmis-

sion>

• Select lever knob <Vehicles with automatic trans-

mission>

• Idle up vacuum hose

• Engine harness

• A/C harness

• Frame harness

• Earth strap

• Engine earth

• Door opening weatherstrip inner

• Floor carpet

• Cab body mounting bolt

CAUTION

Before lifting the vehicle, check to be sure that all
connections between cab body, frame and
engine are separated. Connect sling wires to
suitable bar or frame, fitting protection covers as
necessary.
2. After removing the cab body mounting bolts and

the cab body washers, insert wooden blocks to
the cab body. Gently lift the vehicle with a crane.

<<B>> REAR BODY REMOVAL
1. Remove or disconnect the following parts:

• Fuel filler neck

• Rear body harness

• Rear body mounting bolts and screws

CAUTION

Make sure that the rear body does not hit the cab
body while it is being raised.
2. Hook wires onto the rope hocks on the rear body,

and use a crane to raise the rear body.

REAR GATE

SERVICE SPECIFICATIONS

M1425000300031

Item

Standard value

Rear gate outside handle play mm

Vehicles without high-mounted
stop lamp

0.3

− 1.2 (target value: 0.7)

Vehicles with high-mounted stop
lamp

0.1

− 5.9 (target value: 2.6)

11. Rear body mounting bolt

<<B>>

•

Rear body

Rear body mounting removal steps
(Continued)

REAR GATE

BODY

42-238

ON-VEHICLE SERVICE

REAR GATE PANEL FIT ADJUSTMENT

M1425001000033

ALIGNMENT OF REAR GATE LATCH AND
STRIKER

AC502692AB

Striker

Loosen the striker mounting bolts to adjust the
striker.

ADJUSTMENT OF CLEARANCE AROUND
REAR GATE

•

AC502691AB

Hinge

Rear gate

If the clearance between the rear gate and rear body

is uneven, loosen the mounting bolts on the body
of the rear gate hinge, and then adjust the rear
gate assembly.

•

AC503696

AC502687

AB

Shim

Hinge

: Front of vehicle

If the height of the rear gate and rear body is uneven,

attach the shims to the rear body and hinge
mounting section to adjust the height.

REAR GATE OUTSIDE HANDLE
ADJUSTMENT

M1425000900033

AC503703

AC502690

AC502696

Section A – A

A

A

B

AB

<Vehicles with high-mounted stop lamp>

1. Check that the rear gate outside handle play is

within the standard value range.

Standard value (B):
Vehicles without high-mounted stop lamp:
0.3

− 1.2 mm (target value: 0.7 mm)

Vehicles with high-mounted stop lamp: 0.1

−

5.9 mm (target value: 2.6 mm)

2. If it is outside the standard value range, remove

the rear gate cover (Refer to

P.42-240

).

AC503701

AB

Rear gate handle
controller rod

Rear gate outside
handle holder

3. Remove the rear gate outside handle holder.

Adjust the play by changing the connecting point
between the rear gate handle controller rod and
the rear gate outside handle.

REAR GATE

BODY

42-239

REAR GATE

REMOVAL AND INSTALLATION

M1425001700032

Post-installation Operation
• Rear Gate Fit Adjustment (Refer to

P.42-238

).

AC509877

1

1

3

3

2

2

4

5

5

6

6

AB

7

7

Striker removal

1. Striker

Rear gate removal steps

•

Wiring harness connector connection

2. Rear body rear gate link
3. Rear gate link hook
4. Rear gate assembly

Hinge removal steps

5. Shim (0

− several pieces)

6. Hinge

Damper removal

7. Damper