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EM-94Revision: August 2007
CYLINDER BLOCK
2004 QX56
Measure point “H”.
Piston to Cylinder Bore Clearance
Calculate by using diameter of piston skirt and cylinder bore diameter (direction X, position B).
(Clearance) = (Cylinder bore diameter) – (piston skirt diameter)
If calculation exceeds the limit, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.
3. Cut cylinder bores.
NOTE:
When any cylinder needs boring, all other cylinders must also be bored.
Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT JOURNAL DIAMETER
Measure diameter of crankshaft journals.
If measurement is out of standard, measure the main bearing oil clearance. Then use the undersize bear-
ing. Refer to EM-96, "
MAIN BEARING OIL CLEARANCE" . Distance from the top : 39 mm (1.54 in)
KBIA2545E
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
Rebored size calculation: D = A +B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in)
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CYLINDER BLOCK
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CRANKSHAFT PIN DIAMETER
Measure diameter of crankshaft pin using suitable tool.
If measurement is out of standard, measure the connecting rod
bearing oil clearance. Then use the undersize bearing. Refer to
EM-95, "
CONNECTING ROD BEARING OIL CLEARANCE" .
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
Measure the dimensions at four different points shown on each
journal and pin.
Out-of-roundness is indicated by the difference in dimension
between "X" and "Y" at "A" and "B".
Taper is indicated by the difference in dimension between "A"
and "B" at "X" and "Y".
If the measured value exceeds the standard, correct or replace the crankshaft.
If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bear-
ing or connecting rod bearing. Refer to EM-96, "
MAIN BEARING OIL CLEARANCE" or EM-95, "CON-
NECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT
Place a V-block on a precise flat table to support the journals on
both ends of the crankshaft.
Measure at the No. 3 journal.
While rotating the crankshaft, read the movement of the pointer
on the dial gauge.
Half of the movement shows the runout.
If measurement exceeds the limit, replace the crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method of Measurement
Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod bolt
to the specified torque. Refer to EM-77, "
ASSEMBLY" . Standard : 53.956 - 53.974 mm (2.1243 - 2.1250 in)
PBIC0127E
Limit
Out-of-round (Difference between X and Y)
: 0.002 mm (0.0001 in)
Taper (Difference between A and B)
: 0.002 mm (0.0001 in)
PBIC1685E
Limit : Less than 0.05 mm (0.002 in)
PBIC0129E
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EM-96Revision: August 2007
CYLINDER BLOCK
2004 QX56
Measure the inside diameter of connecting rod bearing.
(Oil clearance) = (Inside diameter of connecting rod bearing) –
(Crankshaft pin diameter)
If clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer to EM-85, "
HOW
TO SELECT MAIN BEARING" .
Method of Using Plastigage
Remove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
Install the connecting rod bearings to the connecting rod and
connecting rod bearing cap, and tighten the connecting rod bolt
to the specified torque.
CAUTION:
Never rotate the crankshaft.
Remove the connecting rod bearing cap and bearings, and
using the scale on the plastigage bag, measure the plastigage
width.
NOTE:
The procedure when the measured value exceeds the repair limit is same as that described in “Method of
Measurement.”
MAIN BEARING OIL CLEARANCE
Method of Measurement
Install the main bearings to the cylinder block and main bearing
cap. Measure the main bearing inside diameter with the bearing
cap bolt tightened to the specified torque. Refer to EM-77,
"ASSEMBLY" .
(Oil clearance) = (Inside diameter of main bearing) – (Crank-
shaft journal diameter)
If the measured value exceeds the repair limit, select main bearings referring to the main bearing inside
diameter and crankshaft journal diameter, so that the oil clearance satisfies the standard. Refer to EM-85
.Standard : 0.020 - 0.039 mm (0.0008 - 0.0015 in)
Limit : 0.055 mm (0.0022 in)
PBIC1642E
KBIA2550E
Standard:
No. 1 and 5 journals
: 0.001 - 0.011 mm (0.00004 - 0.0004 in)
No. 2, 3 and 4 journals
: 0.007 - 0.017 mm (0.0003 - 0.0007 in)
Limit:
No.1 and 5 journals
: 0.021 mm (0.0008 in)
No. 2, 3 and 4 journals
: 0.027 mm (0.0011 in)
PBIC1644E
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Method of Using Plastigage
Remove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
Install the main bearings to the cylinder block and main bearing
cap, and tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the repair limit is same as that described in “Method of
Measurement”.
CRUSH HEIGHT OF MAIN BEARING
When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude. Refer to EM-77, "
ASSEMBLY" for the tight-
ening procedure.
If the standard is not met, replace main bearings.
CRUSH HEIGHT OF CONNECTING ROD BEARING
When the connecting rod bearing cap is removed after being
tightened to the specified torque with connecting rod bearings
installed, the tip end of bearing must protrude. Refer to EM-77,
"ASSEMBLY" for the tightening procedure.
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT DIAMETER
Check for bolts (M9 and M12) installed from lower side using the
following procedure.
NOTE:
Side bolt (M10) is outside the target.
Figure shows M12 bolt.
Measure bolt diameter "d1" from the tip of bolt to dimension "a".
Measure bolt diameter "d2" from the dimension between the tip
of bolt and dimension "b" as base station to dimension "c".
NOTE:
Measure "d2" at that point if narrower part in the threads is
determined by visual check.
Calculate the difference between "d1" and "d2".
KBIA2551E
Standard : There must be crush height
SEM 50 2G
Standard : There must be crush height.
PBIC1646E
KBIA2497E
Page 1981 of 3371
EM-98Revision: August 2007
CYLINDER BLOCK
2004 QX56
M9 bolt
M12 bolt
Replace applicable bolts if outside the limit.
CONNECTING ROD BOLT DIAMETER
Measure diameter "d" at position shown.
When “d” exceeds the limit (when it becomes thinner), replace
the bolt with a new one.Dimension “a” : 9 mm (0.35 in)
Dimension “b” : 15 mm (0.59 in)
Dimension “c” : 20 mm (0.79 in)
Limit : 0.10 mm (0.0039 in)
Dimension “a” : 12 mm (0.47 in)
Dimension “b” : 55 mm (2.17 in)
Dimension “c” : 20 mm (0.79 in)
Limit : 0.15 mm (0.0059 in)
Limit : 7.75 mm (0.3051 in) or less.
SBIA0286E
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SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00IM0
GENERAL SPECIFICATIONS
DRIVE BELTS
EXHAUST MANIFOLD
Unit: mm (in) Cylinder arrangementV- 8
Displacement cm
3 (cu in)5,552 (338.80)
Bore and stroke mm (in)98 x 92 (3.86 x 3.62)
Valve arrangementDOHC
Firing order1-8-7-3-6-5-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio9.8
Compression pressure
kPa (kg/cm
2 , psi)/rpmStandard 1,520 (15.5, 220)/200
Minimum 1,324 (13.5, 192)/200
Differential limit between cylinders 98 (1.0, 14)/200
Cylinder number
Va l v e t i m i n g
Unit: degree
abcde f
232 230 2 48 3 49
SEM 95 7C
PBIC0187E
Tension of drive belts Auto adjustment by auto tensioner
ItemsLimit
Surface distortion Exhaust manifold 0.3 (0.012)
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EM-100Revision: August 2007
SERVICE DATA AND SPECIFICATIONS (SDS)
2004 QX56
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
*: Total indicator reading
Valve Lifter
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*: Approximately 20°C (68 °F) ItemsStandard
Camshaft runout [TIR*] Less than 0.02 (0.0008)
Camshaft cam height “A” Intake & Exhaust 44.465 - 44.655 (1.7506 - 1.7581)
Cam wear limit0.02 (0.0008)
Outside diameter of camshaft journal 25.953 - 25.970 (1.0218 - 1.0224)
Camshaft bracket inside diameter 26.000 - 26.021 (1.0236 - 1.0244)
Camshaft journal clearance 0.030 - 0.068 (0.0012 - 0.0027)
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
SEM 67 1
ItemsStandard
Valve lifter diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Clearance between lifter and lifter guide 0.013 - 0.039 (0.0005 - 0.0015)
Items Hot Cold * (reference data)
Intake 0.304 - 0.416 (0.012 - 0.016) 0.26 - 0.34 (0.010 - 0.013)
Exhaust 0.308 - 0.432 (0.012 - 0.017) 0.29 - 0.37 (0.011 - 0.015)
Page 1984 of 3371
SERVICE DATA AND SPECIFICATIONS (SDS)
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Available Valve Lifter
Unit: mm (in)
Identification (stamped) Mark Thickness
N788 7.88 (0.3102)
N790 7.90 (0.3110)
N792 7.92 (0.3118)
N794 7.94 (0.3126)
N796 7.96 (0.3134)
N798 7.98 (0.3142)
N800 8.00 (0.3150)
N802 8.02 (03.157)
N804 8.04 (0.3165)
N806 8.06 (0.3173)
N808 8.08 (0.3181)
N810 8.10 (0.3189)
N812 8.12 (0.3197)
N814 8.14 (0.3205)
N816 8.16 (0.3213)
N818 8.18 (0.3220)
N820 8.20 (0.3228)
N822 8.22 (0.3236)
N824 8.24 (0.3244)
N826 8.26 (0.3252)
N828 8.28 (0.3260)
N830 8.30 (0.3268)
N832 8.32 (0.3276)
N834 8.34 (0.3283)
N836 8.36 (0.3291)
SEM 75 8G