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FL-12Revision: August 2007
FUEL TANK
2004 QX56
CAUTION:
The quick connector can be disconnected when the tabs
are completely depressed. Do not twist the quick connec-
tor more than necessary.
Do not use any tools to disconnect the quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent any acid liquids such as battery electrolyte, from
getting on the resin tube.
Do not bend or twist the resin tube during connection.
Do not remove the remaining retainer on the hard tube (or
the equivalent) except when the resin tube or the retainer
is replaced.
When the resin tube or hard tube, or the equivalent, is
replaced, also replace the retainer with a new one (white
colored retainer).
To keep the quick connector clean and to avoid damage
and contamination from foreign materials, cover the
quick connector with plastic bags or suitable material as
shown.
15. Remove the four bolts and remove the fuel tank shield.
16. Remove the propeller shaft. Refer to PR-8, "
REAR PROPELLER SHAFT" .
17. Remove the three clips and remove the fuel tank protector at the
front of the fuel tank as necessary to transfer to the new fuel
tank.
18. Disconnect fuel filler hose, and vent hose at the fuel tank side.
PBIC1268E
PBIC0163E
LBIA0388E
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FUEL TANK
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Revision: August 20072004 QX56
19. Remove the fuel tank strap bolts while supporting the fuel tank
with a suitable lift jack.
20. Disconnect the EVAP hose from the molded clip in the top of the fuel tank while lowering the fuel tank.
21. Lower the fuel tank using a suitable lift jack and remove it.
22. If necessary, remove the lock ring using Tool.
23. If necessary, remove the fuel level sensor, fuel filter, and fuel
pump assembly.
CAUTION:
Do not bend the float arm during removal.
Avoid impacts such as dropping when handling the com-
ponents.
INSTALLATION
Installation is in the reverse order of removal.
Connect the quick connector as follows:
–Check the connection for any damage or foreign materials.
–Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.
–After connecting the quick connector, make sure that the con-
nection is secure by checking as follows:
–Pull the tube and the connector to make sure they are securely
connected.
–Visually inspect the connector to make sure the two retainer tabs
are securely connected.
INSPECTION AFTER INSTALLATION
1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for
leaks while applying fuel pressure.
2. Start the engine and rev it above idle, then check that there are no fuel leaks at any of the fuel pipe and
hose connections.
LBIA0387E
Tool number : — (J-46536)
LBIA0389E
PBIC1653E
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FL-14Revision: August 2007
SERVICE DATA AND SPECIFICATIONS (SDS)
2004 QX56
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitEBS00IKR
Fuel tank capacity
105.8 (28 US gal, 23 1/4 Imp gal)
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FSU-1
FRONT SUSPENSION
E SUSPENSION
CONTENTS
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SECTION FSU
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FSU
Revision: August 20072004 QX56 PRECAUTIONS .......................................................... 2
Precautions .............................................................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 4
NVH Troubleshooting Chart ..................................... 4
FRONT SUSPENSION ASSEMBLY ........................... 5
Components ............................................................. 5
ON-VEHICLE SERVICE ............................................. 6
Front Suspension Parts ............................................ 6
Front Wheel Alignment ............................................. 6
PRELIMINARY INSPECTION ............................... 6
GENERAL INFORMATION AND RECOMMEN-
DATIONS .............................................................. 6
THE ALIGNMENT PROCESS .............................. 7
CAMBER AND CASTER ....................................... 7
TOE-IN .................................................................. 8
FRONT WHEEL TURNING ANGLE ..................... 8
COIL SPRING AND SHOCK ABSORBER ............... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 10
Disassembly and Assembly ................................... 10
DISASSEMBLY ................................................... 10
INSPECTION AFTER DISASSEMBLY ............... 10
ASSEMBLY ..........................................................11STABILIZER BAR ..................................................... 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSPECTION AFTER REMOVAL ....................... 12
INSTALLATION ................................................... 12
UPPER LINK ............................................................. 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSPECTION AFTER REMOVAL ....................... 13
INSTALLATION ................................................... 13
LOWER LINK ............................................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
INSTALLATION ................................................... 14
UPPER BALL JOINT AND LOWER BALL JOINT ... 15
Removal and Installation ........................................ 15
Inspection ............................................................... 15
SWINGING FORCE ............................................ 15
TURNING FORCE ............................................... 15
VERTICAL END PLAY ........................................ 16
KNUCKLE ................................................................. 17
On-Vehicle Inspection and Service ......................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSPECTION AFTER REMOVAL ....................... 18
INSTALLATION ................................................... 19
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 20
General Specifications (Front) ................................ 20
Wheel Alignment (Unladen*
1 ) ................................ 20
Ball Joint ................................................................. 21
Wheelarch Height (Unladen*
1 ) .............................. 21
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FSU-2
PRECAUTIONS
Revision: August 20072004 QX56
PRECAUTIONSPFP:00001
PrecautionsEES0010D
When installing the rubber bushings, the final tightening must be done under unladen condition and with
the tires on level ground. Oil will shorten the life of the rubber bushings, so wipe off any spilled oil immedi-
ately.
Unladen condition means the fuel tank, engine coolant and lubricants are at the full specification. The
spare tire, jack, hand tools, and mats are in their designated positions.
After installing suspension components, check the wheel alignment.
Lock nuts are not reusable. Always use new lock nuts for installation. New lock nuts are pre-oiled, do not
apply any additional lubrication.
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PREPARATION
FSU-3
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Revision: August 20072004 QX56
PREPARATIONPFP:00002
Special Service ToolsEES0010E
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Commercial Service ToolsEES0010F
Tool number
(Kent-Moore No.)
Tool nameDescription
ST29020001
(J-24319-01)
Gear arm pullerRemoving ball joint for knuckle spindle
a: 34 mm (1.34 in)
b: 6.5 mm (0.256 in)
c: 61.5 mm (2.421 in)
HT72520000
(J-25730-A)
Ball joint removerRemoving tie-rod outer end
NT694
NT146
Tool nameDescription
Attachment wheel alignment Measure wheel alignment
a: Screw M24 x 1.5 pitch
b: 35 mm (1.38 in) dia.
c: 65 mm (2.56 in) dia.
d: 56 mm (2.20 in)
e: 12 mm (0.47 in)
Spring compressor Removing and installing coil spring
Power toolLoosening bolts and nuts
NT148
NT717
PBIC0190E
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FSU-4
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: August 20072004 QX56
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEES0010G
Use the chart below to help you find the cause of the symptom. Repair or replace parts as necessary.
x: ApplicableReference page
FSU-5FSU-10FSU-5FSU-5FSU-21FSU-6FSU-6FSU-6
PR-3, "
NVH Troubleshooting Chart
"
FFD-7, "
NVH Troubleshooting Chart
"
FAX -4, "
NVH Troubleshooting Chart
"
WT-3, "
NVH Troubleshooting Chart
"
WT-3, "
NVH Troubleshooting Chart
"
BR-5, "
NVH Troubleshooting Chart
"
PS-5, "
NVH Troubleshooting Chart
"
Possible Cause and
SUSPECTED PARTS
Improper installation, looseness
Shock absorber deformation,
damage or deflection
Bushing or mounting deterioration
Parts interference
Spring fatigue
Suspension looseness
Incorrect wheel alignment
Stabilizer bar fatigue
PROPELLER SHAFT
DIFFERENTIAL
AXLE
TIRES
ROAD WHEEL
BRAKES
STEERING
SymptomNoise× × ×××× × × × × × ××
Shake×××× × × ×××××
Vib ratio n××××× × ×× ×
Shimmy× × ×× × × × × ××
Shudder××× ×××××
Poor quality ride or handling××××× ×× ×××
Page 2064 of 3371
FRONT SUSPENSION ASSEMBLY
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Revision: August 20072004 QX56
FRONT SUSPENSION ASSEMBLYPFP:54010
ComponentsEES0010H
1. Washer 2. Spacer 3. Shock absorber mounting insulator
4. Shock absorber bushing 5. Upper seat 6. Coil spring
7. Dust cover 8. Shock absorber 9. Upper link
10. Steering knuckle 11. Cotter pin 12. Drive shaft
13. Lower link 14. Bolt 15. Jounce bumper
16. Cam washer 17. Stabilizer bar 18. Stabilizer bar bushing
19. Stabilizer bar mounting bracket 20. Connecting rod
WEIA0083E