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