Rigtht after the termination of the 2nd globe War, the organization gone back to production vehicles. Fuso coach manufacturing started again, while a tiny three-wheeled cargo vehicle called the Mizushima and a scooter called the Silver Pigeon are in addition developed. But the zaibatsu (Japan's family-controlled industrial conglomerates) were ordered to be dismantled because of the Allied capabilities in 1950, and Mitsubishi Heavy Industries ended up being divided into three regional businesses, each with an involvement in automobile developing: western Japan Heavy-Industries, Central Japan Heavy-Industries, and East Japan Heavy-Industries.
East Japan Heavy-Industries began importing the Henry J, a relatively inexpensive US sedan built by Kaiser engines, in knockdown kit (CKD) type in 1951, and continued to create all of them to Japan for remainder for the automobile's three-year manufacturing run. Similar 12 months, Central Japan Heavy-Industries determined an identical contract with Willys (now had by Kaiser) for CKD-assembled Jeep CJ-3Bs. This deal proved more durable, with certified Mitsubishi Jeeps in manufacturing until 1998, thirty ages after Willys themselves had replaced the design.
Because of the beginning of the 1960s Japan's economy is gearing up; wages were rising therefore the idea of household motoring had been taking off. Central Japan Heavy-Industries, now-known as Shin Mitsubishi Heavy-Industries, had currently re-established an automotive department with its headquarters in 1953. Now it was prepared present the Mitsubishi 500, a mass-market sedan, to fulfill the latest demand from consumers. They then followed this in 1962 utilizing the Minica kei vehicle therefore the Colt 1000, the initial of the Colt type of family automobiles, in 1963. In 1964, Mitsubishi launched its largest passenger sedan, the Mitsubishi Debonair as an extravagance vehicle mostly for Japanese markets, and ended up being used by senior Mitsubishi professionals as a company vehicle.
West Japan Heavy-Industries (now rebranded Mitsubishi Shipbuilding & Engineering) and East Japan Heavy-Industries (now Mitsubishi Nihon Heavy-Industries) had also expanded their automotive departments into the 1950s, as well as the three are re-integrated as Mitsubishi significant sectors in 1964. Within 36 months its output is over 75,000 automobiles annually. Following the successful introduction of very first Galant in 1969 and comparable gains featuring its commercial automobile unit, it absolutely was decided that business should develop one operation to pay attention to the automotive markets. Mitsubishi engines company (MMC) was formed on April 22, 1970 as a wholly had subsidiary of MHI in leadership of Tomio Kubo, a successful professional from the plane division.
The logo design of three purple diamonds, distributed to over forty other businesses within the keiretsu, predates Mitsubishi engines itself by virtually a hundred years. It had been picked by Iwasaki Yatar, the creator of Mitsubishi, as it had been suggestive associated with emblem of Tosa Clan just who first employed him, and because his or her own family crest was three rhombuses piled atop each other. Title Mitsubishi () is composed of two areas: "mitsu" indicating "three" and "hishi" (which becomes "bishi" under rendaku) indicating "water caltrop" (also known as "water chestnut"), and therefore "rhombus", which is mirrored when you look at the company's logo..
In October 2005, Mitsubishi engines Australia launched the Mitsubishi 380 into Australian market whilst the replacement its long-running Mitsubishi Magna, and the only vehicle becoming built at its Australian construction plant at Clovelly Park. Despite an investment of A0 million establishing the car, initial marketing forecasts shown upbeat; after only six months Mitsubishi scaled back once again manufacturing from 90/day, and reduced the employed few days from five days to four. It stayed a continuous issue within the Australian automobile business regarding whether this could be enough to displace the plant to profits and ensure their long-lasting success.
The drop in local product sales couldn't feel mitigated by exports outside the Australian and New Zealand market. On 5 February 2008, Mitsubishi Motors Australian Continent launched it might be shutting down its Adelaide installation plant by the end of March. Between 700 and 1,000 direct work would-be lost or more to 2,000 employment are destroyed in industries supporting Mitsubishi's neighborhood production operations.
Following the acquisition by mother or father company Chrysler of a 15 per cent fascination with Mitsubishi Motors Corporation in 1971, Chrysler Australia started design Mitsubishi-designed Chrysler-branded cars, specifically the Chrysler Valiant Galant (later on Chrysler Galant), in line with the 1972--1977 Mitsubishi Galant and Chrysler Sigma, a variant associated with the 1977--1985 Mitsubishi Galant. In 1979, Mitsubishi engines company and Mitsubishi firm each obtained a-one 6th equity in Chrysler Australian Continent. The collective price taken care of the two-sixths equity had been A million. On 30 April 1980, the 2 Japanese businesses presumed 98.9 % control if you are paying a further million to obtain Chrysler's continuing to be 65 percent share. The remaining 1.1 percentage occured by 690 regional investors. The organization name ended up being altered to Mitsubishi Motors Australian Continent Limited on 1 October 1980. Production of the most popular Sigma range of automobiles continuing under the Mitsubishi title until 1987 having its eventual replacement, the Magna, having been introduced in 1985. Colt manufacturing, which have commenced in 1982, finished in 1990, with no in your area manufactured replacement.
The Magna, like its forebear the Sigma, had been on the basis of the Japanese Galant. Input from MMAL led to a wider vehicles compared to the Japanese donor design to accommodate the Australian marketplace and also to contend with the favorite Ford Falcon and Holden Commodore. A station truck variant was included with the model lineup in 1987. The Magna got several design refreshes throughout the 1990s including an extra variation named Verada. However, by the very early 2000s, it was clear the Magna / Verada range, today with its third iteration have aged significantly. A facelift toward Magna / Verada range in 2003 did not carry selling. After lobbying from Mitusubishi engines Australia brief (MMAL) endorsement for building of a new vehicle is given by Mitsubishi Motors Corporation. Capital had been supplied to re-engineer the Tonsley Park plant because of the result that a new automobile, the Mitsubishi 380, was brought to industry in late 2005.
In 2003 MMAL attained endorsement from MMC to produce Mitsubishi Research and developing Australia (MRDAus) with a budget of million. MRDAus was to end up being the fourth international Mitsubishi Research and developing center. MMAL's proving surface at Tailem Bend would be to be enhanced such as the inclusion of a higher rate egg-shaped and numerous other proving floor business while the evaluation and Proving team's laboratories at MMAL headquarters in Tonsley Park was also to-be enhanced. MRDAus was initially tasked with doing Mitsubishi 380 evaluation and Proving prior to the beginning of amount manufacturing. MRDAus additionally negotiated significant tasks share the evaluation and proving regarding the PS41L, the codename for a stretched 380 when it comes to US market. Unfortuitously aided by the economic problems dealing with MMC globally and cancelling of this PS41L system MRDAus had been incapable of reach its complete potential. In belated 2004 after growing to 90 employees the MRDAus development is stopped ahead of the 380 ended up being even established. A security fence around all of the extended Tailem flex webpages is almost complete and the earthworks for the high speed egg-shaped had started when perform was stopped in 2004.
Mitsubishi Motors business's financial and legalities considered difficult on MMAL, with community perception associated with viability of this organization achieving an all-time reduced in 2004. Company study performed in mid-2004 unveiled that approximately four out of each and every five thought that Mitsubishi would cease manufacturing in Australian Continent.
The detachment of DaimlerChrysler from its participation with Mitsubishi Motors Corporation in 2004, together with the revitalisation program that needed the closing associated with Lonsdale system plant, would not help the public's perception of MMAL as a viable providers.
MMAL ended 2004 with a stockpile of approximately 4,000 unsold Magnas and Veradas. To restore consumer confidence inside brand name and to clear the design backlog, a series of tvs commercials began airing in December 2004. Centred on Mitsubishi Australia's then ceo, Tom Phillips, the ads presented the introduction of an industry-first five-year/130,000 kilometre guarantee. Mitsubishi reworked a slogan from previous Chrysler chairman Lee Iacocca, concluding their particular advertisements using tagline, "if you're able to see a better-built, better-backed car anywhere, then buy it". The promotion effectively boosted selling and let the backlog to-be eliminated.
The Mitsubishi 380, the successor car to the Magna, raised hopes for future years of MMAL whenever launched. Hopes stemmed through the purchases success that Magna practiced when it was launched therefore the proven fact that the Australian car markets was growing at that time. But the 380 marketed poorly from its introduction and didn't meet anticipated marketing goals. This triggered a reduction in everyday production amount from 180 to 50 motors a day, alongside more reductions inside workforce.
The "make or break" Mitsubishi 380 began manufacturing in 2005, lasting not as much as three years in the marketplace.
Purchases of various other Mitsubishi Motors Corporation vehicles began to show improvement in Asian and European markets as newer vehicles had been introduced during 2006. These cars had been in addition launched to the Australian markets, improving MMAL's Australian purchases into the portions why these motors occupied, though this performed absolutely nothing to help their purchases of locally manufactured item.
Cessation of local manufacturing and corporate restructure
On 5 February 2008, it was announced that MMAL would cease production of the 380 on Tonsley playground plant, good at the termination of March 2008. The two-page statement revealed announced they might go after a "full import method" the Australian market as a result of unviable 380 sales. The past Mitsubishi 380 sedan kept manufacturing range on 27 March 2008. Coinciding using last vehicles to leave the line is the redundancy around 500 employees, with another 430 keeping for another one year. Those leftover decommissioned the plant and produced a stockpile of extra parts destined to last a decade.
By late 2009, MMAL have eliminated the final piece of production equipment from Tonsley Park assembly plant. Ownership associated with plant had been handed over towards the federal government of Southern Australia on 16 December 2009.
The disused Mitsubishi plant in Adelaide
In addition, MMAL began a restructure of the staying divisions of company. This restructure concluded in mid-2009 and spotted workforce figures decreased to around 300 through redundancy and outsourcing.
Most of the staying team are involved with business and advertising activities, though MMAL retains some capacity to perform any build changes that may be needed to compliment Mitsubishi engines firm's international items into the Australian markets.
In 1996 the 3.0 V6 system is revised, keeping SOHC but changing to 24v. At the same time the ignition system had been enhanced from old distributor program to solid state coil packs. Capacity to 177 bhp (132 kW). The 2.4 system was introduced as a smaller sized power-plant offered only on SWB human anatomy with revised minor interior and exterior.
The Pajero advancement ended up being introduced in October 1997, which was created responding to newer entry requirement when it comes to Paris -- Dakar Rally's T3 Class. The Pajero Evolution arrived standard with a 3.5-liter 24-valve DOHC V6 with Mitsubishi Innovative device time and Electronic raise Control (MIVEC). A, dual plenum variable intake assisted boost energy and a independent back suspension made the ride even smoother.
In 1998, vehicles destined for General Export therefore the GCC (Gulf Cooperation Council countries) got a facelift. Wider fenders, new headlights, grille, bumper, fog lighting and sidesteps had been all the main redesign. The broad fenders are often known as "blister flare fenders". Driver and front-passenger SRS airbags had been made traditional on systems loaded with the 3.5-liter DOHC V6 system, whilst still remaining recommended on GLS systems with the 3.0-liter SOHC V6. 1080 of those units are furthermore put together in Iran by Bahman Khodro Group before becoming removed manufacturing. An upgraded indoor wood trim had been provided on 3.0-liter GLS and 3.5-liter brands. A leather-wrapped or leather and timber trim steering wheel has also been offered, alongside an upgraded suspension system and steering program. The 3.0-liter 12-valve SOHC engine was now available with a 24-valve setup. Systems without wider fenders stayed as base models (GLX), readily available with a 2.4-liter 16-valve DOHC motor, creating 147 hp (110 kW). The 3.0-liter 12-valve system was optional on these GLX products, and remained the bottom system from the GLS.
The 2nd generation had been introduced on 22 January 1991 and made until 1999. It retained the 2 system types, but build had been rounder plus city-friendly compared to past bulky model. The 3.0 L V6 gas engine is retained, available nowadays with a 24-valve mind, effective at 136 kW (177 hp/185 PS), as the 2.5 turbodiesel's power is a little risen to 73 kW (98 hp/99 PS). In 1993, the Pajero is slightly restyled, and bigger motors were launched, a 3.5 L V6 with 153 kW (215 hp/208 PS) and a 2.8 L SOHC turbodiesel rated at 92 kW (123 hp/125 PS). These variations introduced Mitsubishi's Super Select four-wheel-drive program (known as Active-Trac in the us), with an electric transfer change might separate power between both axles without the necessity to prevent the car. It worked at boosts to 100 km/h (62 mph).
The very first generation Pajero has also been advertised once the Hyundai Galloper in Korea, European countries and GCC Countries, as the second generation was at manufacturing somewhere else.
This design Pajero stayed in production in Asia till 2012 because the Pajero SFX; the latest generation is sold as the Montero. Within the Philippines it's marketed once the Pajero "Field Master" 4x2 aided by the 2.8L TD system, alongside the 4th generation Pajero. The 4X4 variation is removed from production in 1999. Additionally it is manufactured in Colombia from perfect Knock Down section (CKD) till 2012, with a 2.4l 16 valve SOHC (130 PS) or 3.0l 12 valve V6 (148 PS), both motors can be obtained as a three-door tough top, the five-door wagon only with the 3.0-liter V6.
In Venezuela, the second generation was made of 1992 to 1995 in name of Mitsubishi Montero, it absolutely was for sale in long and short wheel base. From 1996 to 2009 their name had been altered to Mitsubishi Montero Dakar, it was best obtainable in brief wheel base with 6G72 engine and handbook five-speed transmission.
- Purpose and quick overview
- Aligning wheels ensures proper tire wear, handling, fuel economy, and vehicle safety. For Mitsubishi Fuso FK/FM trucks (6M60 engine irrelevant to alignment), adjustments target toe, camber, and caster (and thrust angle); exact target values must come from the factory alignment specifications for the specific model/year—use the workshop manual for numbers.
- Safety first
- Use wheel chocks on rear wheels and park on level concrete.
- Use a heavy-duty jack and rated jack stands placed on the axle or recommended lift points — never rely on the jack alone.
- Wear safety glasses and gloves; keep bystanders clear.
- Block wheels and ensure parking brake is engaged.
- If using an alignment rack, follow the rack manufacturer’s safety procedures.
- Basic tools (what they are, detailed description, how to use)
- Hydraulic floor jack (2–3 ton for light trucks / 3+ ton for medium trucks)
- Description: hydraulic lift with saddle; rated capacity printed on side.
- Use: place under axle or manufacturer lift point, pump handle to raise; lower slowly by turning release valve. Lift only to place jack stands, not to hold the vehicle for work.
- Jack stands (heavy-duty; rated appropriately)
- Description: steel stands with locking pin or ratchet bar, capacity must exceed axle load.
- Use: set under axle or chassis frame, adjust to contact point and lock; always test stability.
- Wheel chocks
- Description: rubber or metal wedges.
- Use: place front and rear of wheels left on ground to prevent roll.
- Torque wrench (large range, accurate)
- Description: click-style or digital wrench with appropriate socket sizes.
- Use: tighten wheel nuts and fasteners to specified torque in the workshop manual; set torque before applying and listen for click.
- Socket set and breaker bar
- Description: metric sockets, extensions, swivel adaptors.
- Use: remove and install nuts/bolts; use breaker bar for stubborn fasteners.
- Pliers, adjustable wrench, screwdrivers, hammer
- Description: general hand tools.
- Use: for cotter pins, retaining clips, light persuasion.
- Pry bar and strong lever
- Description: steel bars for leverage.
- Use: check play in joints and align components when adjusting.
- Tape measure (metric) and straight edge
- Description: 3–8 m tape, marked metrics.
- Use: measure toe distances, wheelbase, and thrust angle references.
- Chalk or marker
- Description: aerosol or grease pencil.
- Use: mark current toe/steering wheel position, alignment reference points.
- String and string-line or toe plates (toe plates: flat metal plates)
- Description: string method uses long string and turnbuckles; toe plates are metal plates placed at wheel rim.
- Use: measure toe across front and rear of rims by comparing measurements; string method needs anchor points on chassis or floor and works without specialized gauges.
- Camber/caster gauge or digital inclinometer
- Description: handheld inclinometer or wheel-mounted camber/caster gauge.
- Use: attach to wheel rim or hub, zero on known vertical, read camber and caster angles per manual.
- Steering wheel centering tool or spoke wheel indicator
- Description: clamps or marks steering wheel position relative to steering column.
- Use: ensure steering wheel is centered before and after adjustment to avoid offset.
- Grease gun
- Description: manual grease dispenser with fittings.
- Use: lubricate tie rod ends and ball joints if serviceable; some play is fixed by worn parts not greaseable.
- Feeler gauges and dial indicator (for kingpin/steering wear)
- Description: thin metal blades (feeler) and dial indicator (measures runout/play).
- Use: measure free play and axial/backlash in steering components to detect worn parts.
- Optional / specialty alignment equipment (why required)
- Four-wheel alignment machine (laser or camera-based)
- Why: gives fast, accurate readings of camber, caster, toe, thrust angle. Recommended for trucks for precision and saving time.
- How used: wheels get clamps/targets; machine reads and guides adjustments to specs.
- Alignment turntables / slip plates (for front wheels)
- Why: reduce friction, allow accurate steering movement and toe measurement while wheels turn.
- How used: place under front wheels; roll vehicle to center turntables or follow machine instructions.
- Truck-specific wheel adapters or hub mount plates
- Why: mounting targets/clamps to large truck rims/hubs may require adapters.
- How used: secure target plates to hub per alignment machine instructions.
- Kingpin gauge / steering axis gauge
- Why: measure kingpin inclination/wear on solid axles; important for heavy truck geometry.
- How used: follow gauge instructions to assess kingpin condition and SA inclination.
- Cam bolt kits, eccentric bolts, shims (replacement/adjustment hardware)
- Why: many heavy trucks require eccentric bolts or shims to change camber/caster; you may need new hardware if old is damaged.
- How used: remove worn bolts/shims, fit new ones to reach desired geometry.
- Preparation steps before measuring (how to use the tools here)
- Check tire pressure and inflate to recommended pressures; uneven pressure alters readings.
- Check tires for uneven wear, bulges, or damage; severely worn tires must be replaced before alignment.
- Ensure vehicle ride height is correct (suspension loaded as per manual) — use jack stands to set normal ride height if necessary.
- Center the steering wheel: use chalk to align wheel spokes or use a steering wheel centering tool.
- Remove excess load from truck bed/cab that would change suspension sag; load should match manual condition if specified.
- Inspection for worn parts (what to check, why, how)
- Inspect tie rod ends and drag link for play using pry bar and by grasping wheel at 3 and 9 o’clock and attempting to move in/out; any free play indicates wear and replacement.
- Check steering gearbox for excessive play; grab steering wheel and rock—if there’s free play beyond spec, gearbox/sector may be worn.
- Check kingpins/kingpin bushings (solid axle trucks) for vertical and radial play using dial indicator or by rocking wheel hub; replace if beyond spec.
- Inspect ball joints, control arm bushings, radius rods, and track rods for torn boots, play, or corrosion; worn bushings cause alignment drift.
- Check wheel bearings for play and hub runout; worn bearings lead to steering wobble and alignment issues.
- Replace any worn components before attempting alignment — alignment adjustments only hold if suspension components are sound.
- Measurement of alignment angles (how to do basic toe with simple tools)
- Toe measurement using toe plates or string method:
- Toe plates: attach plates to front edges of rims; use tape measure to measure distance between plates at front and rear; toe = (rear measurement - front measurement) / number of sides (depending on convention); set to spec.
- String method: place strings parallel along vehicle sides at hub center height, secure to floor anchors or jack stands; measure distance from string to rim at front and rear of each wheel; calculate toe differential and adjust.
- How to use tape measure: pull tight, measure to same wheel hub height, and take consistent reference points on rim.
- Keep steering centered while measuring; use steering wheel lock to hold center position.
- Camber and caster:
- Use camber/caster gauge or digital inclinometer attached to rim or hub according to gauge instructions; zero the gauge vertically and follow manual to read camber or caster.
- Adjust camber/caster using eccentric bolts, adjustable ball joints, or shim packs depending on truck design; consult manual for location of adjusters.
- Thrust angle:
- Measure rear axle centerline vs. vehicle centerline (use tape measure between hub centers); thrust angle is the direction rear axle points relative to centerline; adjust toe on rear axle (if adjustable) or adjust front toe to correct thrust.
- How to adjust (general methods and how to use tools)
- Toe adjustment (typical method using tie-rod ends)
- Loosen lock nuts on tie-rod ends with appropriate sockets/wrenches.
- Turn tie-rod body or use inner/outer tie-rod threads to lengthen/shorten until toe measurements match spec.
- Use tape measure or alignment machine to monitor measurement while adjusting.
- Tighten lock nuts to specified torque with torque wrench and fit new cotter pins if provided.
- Camber/caster adjustment
- Identify type of adjuster: eccentric bolt at lower arm, adjustable control arm, or shim under axle beam.
- Use appropriate socket/wrench to rotate eccentric bolt or change shims; measure with camber gauge after small adjustments.
- For shims, raise or lower axle by adding/removing shims per manual; this requires axle support and torqueing new hardware to spec.
- Steering axis/kingpin
- If worn beyond spec, removal and replacement of kingpin bushings or kingpin assembly is required; this is a major repair requiring press equipment or specialized tools.
- After any adjustment, always tighten lock nuts and torque to manufacturer values.
- Rechecking and finishing steps
- Re-measure all angles after adjustments in the same order; toe is usually adjusted last.
- Tighten all fasteners to specified torque values with the torque wrench.
- Reinstall any covers, caps, and cotter pins.
- Lower vehicle carefully, remove jack stands, and road test at low speed to confirm handling; recheck wheel alignment after 10–20 km.
- Check wheel nut torque after the road test.
- Common replacement parts and why they might be needed (what to replace, symptoms, and why)
- Tie rod ends / drag link
- Why: primary toe adjustment points; wear causes play, wandering, and uneven tire wear.
- Replace if there’s axial or radial play, torn boots, or looseness.
- Ball joints / control arm bushings
- Why: allow suspension articulation; worn joints affect camber and caster and create noise and uneven wear.
- Replace if boot torn, grease leaked, or measured play exceeds spec.
- Kingpins and bushings (solid front axle)
- Why: wear causes steering shimmy and inability to hold alignment; critical on heavy trucks.
- Replace if vertical/runout/play exceeds spec; replacement often requires press or specialist.
- Wheel bearings and hub assemblies
- Why: excessive runout or play causes inaccurate readings and premature tire wear.
- Replace if noise, heat, or play detected.
- Steering gearbox or sector shaft
- Why: excessive internal play affects steering center and alignment; sometimes rebuild or replace is required.
- Camber/caster shims or eccentric bolts
- Why: damaged or seized adjusters prevent correct alignment; replace to gain adjustability.
- Wheel rims or tires
- Why: bent rims or uneven tires cannot be aligned properly; replace as needed.
- Why extra tools or professional help may be required
- Presses and specialized removal tools are required for kingpin or pressed-in bushings — not typically available to beginners.
- Alignment machines provide precise readings that are difficult to match with manual methods; for heavy trucks, professional alignment shops or dealer equipment is strongly recommended.
- If you find worn steering or suspension components beyond simple replacements, a professional shop with heavy-duty tools, lifting equipment, and alignment racks is safer and more accurate.
- Final practical tips and cautions
- Always replace worn components first — new adjustments won’t hold on worn parts.
- Keep a written log of initial measurements and final measurements.
- Use new cotter pins and thread locker where applicable.
- If unsure about any measurement or replacement, use a professional alignment shop—truck geometry errors have safety consequences.
- Always consult the specific Mitsubishi Fuso service manual for FK/FM model alignment specifications, torque values, and adjustment procedures before starting.
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- **Safety Gear**
- **Safety Glasses**: Protects your eyes from debris.
- **Gloves**: Protects your hands from sharp objects and oils.
- **Basic Tools Required**
- **Socket Set**: Essential for removing bolts. Use a ratchet and the appropriate socket size for various components.
- **Wrench Set**: Useful for areas where a socket won’t fit. Ensure you have both standard and metric sizes.
- **Torque Wrench**: Ensures bolts are tightened to manufacturer specifications, preventing damage.
- **Pliers**: To grip or twist wires and small components.
- **Screwdrivers**: Flathead and Phillips for removing or securing covers and small parts.
- **Specialized Tools Required**
- **Valve Spring Compressor**: This tool compresses the valve springs, making it easier to remove and install valves without damaging them. It is crucial for safely handling springs.
- **Feeler Gauge**: Measures gap sizes for valve clearances. Necessary for proper adjustment after spring replacement.
- **Magnetic Pickup Tool**: Helpful for retrieving dropped bolts or components in tight spaces.
- **Additional Tools (if necessary)**
- **Harmonic Balancer Puller**: Might be needed if the crankshaft pulley needs removal for accessing certain components.
- **Timing Light**: For checking timing settings post-assembly.
- **Preparation Steps**
- Disconnect the battery to ensure safety while working.
- Remove the engine cover and any components blocking access to the valve springs (e.g., intake manifold, rocker arms).
- Take photos of the assembly as you disassemble for easier reassembly.
- **Replacing Valve Springs**
- **Inspect Existing Springs**: Check for wear or damage (cracks, bending). If damaged, replacements are necessary.
- **Remove Old Springs**: Use the valve spring compressor to compress the spring, then remove the keepers and spring. Repeat for all springs.
- **Install New Springs**: Place new springs in position, use the compressor to secure them, and replace keepers.
- **Replacement Parts Needed**
- **Valve Springs**: If existing springs are worn or damaged, new ones are required. Choose OEM or high-quality aftermarket springs for reliability.
- **Retainers and Keepers**: These may also need replacement if they show signs of wear.
- **Gasket Set**: If the valve cover gasket is damaged during disassembly, replace it to prevent oil leaks.
- **Reassembly and Final Checks**
- Reassemble in reverse order, ensuring all components are torqued to specifications.
- Use the feeler gauge to check valve clearances and adjust if necessary.
- Reconnect the battery and start the engine, checking for any abnormal noises or leaks.
- **Post-Work Inspection**
- Monitor the engine for a period of time after the job is completed to ensure everything is functioning correctly and there are no leaks or issues.
This guide provides a structured approach for beginners to replace valve springs on a Mitsubishi 6M60 engine while emphasizing safety and the necessity of specific tools.
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1) Safety & prep
- Work on a cold engine, park on level ground, set parking brake, chock wheels. Wear gloves/eye protection and ventilate when using cleaners.
- Gather: service manual (for fuse/torque specs), basic hand tools, multimeter, scan tool able to command actuators, bench 12 V supply (or diagnostic output), throttle-body/parts cleaner safe for sensors, replacement AAV gasket or valve if needed.
2) What the auxiliary air valve (AAV) is and why it matters (theory)
- Function: the AAV is a controlled bypass that meters extra intake air around the throttle during start and idle so the ECU can achieve a stable idle and cold fast-idle. The ECU opens/closes it according to inputs (coolant temp, intake air temp, engine speed, load) to maintain target idle airflow.
- Control: on 6M60 variants the AAV is an electrically driven device (solenoid/stepper/actuator) commanded by the ECU (often PWM or pulse steps). It converts the ECU command into a variable bypass opening.
- Fault effect: if the valve is sticking, clogged, mechanically failed, or electrically dead, idle airflow is wrong. Symptoms include rough or high/low idle, stalling on cold start, slow idle recovery after load, and related DTCs. Cleaning or replacing restores correct bypass airflow and corrects the ECU’s ability to control idle.
3) System diagnosis (do this in order)
a. Read fault codes with a diagnostic tool. Note AAV-related codes and freeze-frame data.
b. Observe live data: coolant temp, commanded AAV position, actual AAV feedback (if present), and idle speed.
c. Visual inspection: check wiring harness and connector for corrosion, broken pins, or rodent damage; inspect vacuum hoses and intake for leaks.
d. Electrical checks: with connector disconnected, measure supply voltage and ground as you crank/run; back-probe while commanding the valve with the scan tool. Measure coil resistance and compare to manual spec.
e. Functional command test: use the scan tool to command the AAV open/close while observing movement and engine response. If the ECU commands but valve doesn’t move or no change in airflow, the valve is suspect.
4) Remove AAV (order of operations)
- Isolate battery negative.
- Locate the AAV on the intake manifold (refer to manual for exact location). Label vacuum hoses and electrical connectors.
- Remove electrical connector and any vacuum hoses (cap them if needed to avoid contamination).
- Remove mounting fasteners and take the valve off with its gasket. Keep orientation and note any linkage or valve plunger orientation.
- Inspect mating surfaces and intake port for carbon/deposits.
5) Bench test & inspect
- Check coil resistance with a meter (compare to manual).
- Apply appropriate bench voltage/pulse (use caution, use the specification voltage/pulse method from manual) to verify plunger/stepper movement and free travel. If it’s a solenoid, it should pull; if a stepper, it should step smoothly.
- Inspect for carbon build-up, binding, damaged plunger/seal, broken return spring, or seized mechanism. If electrical function is absent or mechanical wear/damage present, replace.
6) Clean vs Replace
- Cleaning: if mechanical sticking from carbon is the only problem and electrical test is good, clean carefully with throttle-body/intake-safe solvent. Avoid aggressive scraping that damages seats/seals. Operate the plunger during cleaning to free deposits, then dry completely.
- Replace: if electrical tests fail, movement is inconsistent, sealing surfaces are damaged, or the valve is cheap relative to labor — replace with an OEM or equivalent part.
7) Refit and reconnect
- Fit a new gasket (recommended) and reinstall valve in original orientation. Tighten fasteners to the workshop manual torque (do not guess).
- Reconnect vacuum hoses and electrical connector.
- Reconnect battery negative.
8) Relearn, verify & final checks
- Clear DTCs.
- Start engine and allow warm-up. Let the ECU exercise the valve; use the scan tool to command open/close and watch live feedback and idle response.
- Check for intake leaks around the valve flange and for correct idle speed under various temps/load (AC on/off).
- Road test to confirm driveability and ensure fault codes do not return.
9) Why the repair fixes the fault (succinct)
- Problem: a stuck, clogged, or electrically failed AAV prevents the ECU from controlling bypass airflow, so the engine receives too much or too little idle air. The ECU compensates incorrectly or cannot hold target idle, producing rough idle, stalling, or wrong idle speed.
- Fix: cleaning or replacing the valve restores its mechanical freedom and electrical function, which allows the ECU to modulate bypass airflow correctly in response to temp/load signals. Proper sealing and restored movement eliminate uncontrolled leaks and restore predictable air metering, resolving the idle/stall symptoms.
10) Final notes (concise)
- Always use correct diagnostic and bench-test procedures from the factory manual. Do not force or file seats; improper reassembly or wrong torques cause leaks or damage. Replace gaskets and use OEM parts when possible for predictable performance.
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