EC-628Revision: October 2005
IGNITION SIGNAL
2005 QX56
8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Check harness continuity between condenser terminal 2 and ground.
Refer to Wiring Diagram.
3. Also check harness for short to power.
OK or NG
OK >> GO TO 9.
NG >> Repair open circuit or short to power in harness or connectors.
9. CHECK CONDENSER
Refer to EC-629, "
Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> Replace condenser.
10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV
1. Turn ignition switch OFF.
2. Reconnect all harness connectors disconnected.
3. Disconnect ignition coil harness connector.
4. Turn ignition switch ON.
5. Check voltage between ignition coil terminal 3 and ground with
CONSULT-II or tester.
OK or NG
OK >> GO TO 12.
NG >> GO TO 11.
11 . DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E2, F32
Harness for open or short between ignition coil and harness connector F32
>> Repair or replace harness or connectors. Continuity should exist.
Voltage: Battery voltage
BBIA0359E
PBIB0138E
IGNITION SIGNAL
EC-629
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Revision: October 20052005 QX56
12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.
3. Also check harness for short to power.
OK or NG
OK >> GO TO 13.
NG >> Repair open circuit or short to power in harness or connectors.
13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminals 46, 60, 61, 62, 65, 79, 80, 81 and ignition coil terminal
1.
Refer to Wiring Diagram.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 14.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
14. CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to EC-629, "
Component Inspection" .
OK or NG
OK >> GO TO 15.
NG >> Replace ignition coil with power transistor.
15. CHECK INTERMITTENT INCIDENT
Refer to EC-156, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>>INSPECTION END
Component InspectionUBS00L1D
IGNITION COIL WITH POWER TRANSISTOR
CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
4. If NG, replace ignition coil with power transistor.
If OK, go to next step.
5. Turn ignition switch OFF.
6. Reconnect all harness connectors disconnected.Continuity should exist.
Continuity should exist.
Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)]
1 and 2 Except 0 or ∞
1 and 3
Except 0
2 and 3
PBIB0847E
EC-630Revision: October 2005
IGNITION SIGNAL
2005 QX56
7. Remove fuel pump fuse in fuse block No. 1 to release fuel pres-
sure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pres-
sure applies again during the following procedure.
8. Start engine.
9. After engine stalls, crank it two or three times to release all fuel
pressure.
10. Turn ignition switch OFF.
11. Remove all ignition coil harness connectors to avoid the electri-
cal discharge from the ignition coils.
12. Remove ignition coil and spark plug of the cylinder to be checked.
13. Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
14. Connect spark plug and harness connector to ignition coil.
15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm
between the edge of the spark plug and grounded metal portion
as shown in the figure.
16. Crank engine for about 3 seconds, and check whether spark is
generated between the spark plug and the grounded metal por-
tion.
CAUTION:
Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the electrical discharge voltage
becomes 20kV or more.
It might cause to damage the ignition coil if the gap of more than 17 mm is taken.
NOTE:
When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.
CONDENSER
1. Turn ignition switch OFF.
2. Disconnect condenser harness connector.
3. Check resistance between condenser terminals 1 and 2.
Removal and InstallationUBS00L1E
IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-26, "IGNITION COIL" . Spark should be generated.
BBIA0380E
PBIB2325E
Resistance Above 1 MΩ at 25°C (77°F)
PBIB0794E
EI-1
EXTERIOR & INTERIOR
I BODY
CONTENTS
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SECTION EI
A
B
EI
Revision: October 20052005 QX56 PRECAUTIONS .......................................................... 3
Service Notice .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS ........... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REPAIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS ................................................................. 7
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
OVERHEAD CONSOLE (FRONT AND REAR) ..... 8
SEATS ................................................................... 8
UNDERHOOD ....................................................... 8
Diagnostic Worksheet .............................................. 9
CLIP AND FASTENER ..............................................11
Description ..............................................................11
FRONT BUMPER ..................................................... 13
Removal and Installation ........................................ 13
REAR BUMPER ....................................................... 15
Removal and Installation ........................................ 15
FRONT GRILLE ........................................................ 17
Removal and Installation ........................................ 17
COWL TOP ............................................................... 18
Removal and Installation ........................................ 18
FRONT FENDER ...................................................... 20
Removal and Installation ........................................ 20OVER FENDER ......................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSTALLATION ................................................... 21
FENDER PROTECTOR ............................................ 23
Removal and Installation ........................................ 23
FRONT ................................................................ 23
LICENSE LAMP FINISHER ...................................... 24
Removal and Installation ........................................ 24
RUNNING BOARDS ................................................. 25
Removal and Installation ........................................ 25
REAR SPOILER ........................................................ 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
ROOF RACK ............................................................. 27
Removal and Installation ........................................ 27
DOOR OUTSIDE MOLDING ..................................... 28
Removal and Installation ........................................ 28
............................................................................ 28
............................................................................ 29
SIDE GUARD MOLDING .......................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSTALLATION ................................................... 30
DOOR FINISHER ...................................................... 32
Removal and Installation ........................................ 32
FRONT DOOR .................................................... 32
REAR DOOR ....................................................... 33
BODY SIDE TRIM ..................................................... 35
Removal and Installation ........................................ 35
LOWER DASH SIDE FINISHER ......................... 35
CENTER PILLAR LOWER FINISHER ................ 36
CENTER PILLAR UPPER FINISHER ................. 36
FRONT PILLAR FINISHER ................................. 36
KICKING PLATES ............................................... 36
MUDGUARD FINISHERS ................................... 36
DOOR PARTING SEALS .................................... 36
FLOOR TRIM ............................................................ 37
Removal and Installation ........................................ 37
EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
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Revision: October 20052005 QX56 PRECAUTIONS .......................................................... 3
Precautions for Drain Engine Coolant ...................... 3
Precautions for Disconnecting Fuel Piping .............. 3
Precautions for Removal and Disassembly ............. 3
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 3
Precautions for Assembly and Installation ............... 3
Parts Requiring Angular Tightening ......................... 3
Precautions for Liquid Gasket .................................. 4
REMOVAL OF LIQUID GASKET SEALING .......... 4
LIQUID GASKET APPLICATION PROCEDURE ..... 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 9
NVH Troubleshooting —Engine Noise ..................... 9
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 10
ENGINE ROOM COVER ...........................................11
Removal and Installation .........................................11
REMOVAL ............................................................11
INSTALLATION ....................................................11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Tension Adjustment ................................................ 12
Removal and Installation ........................................ 12
DRIVE BELT ....................................................... 12
INSTALLATION ................................................... 13
Drive Belt Auto Tensioner and Idler Pulley ............. 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
AIR CLEANER AND AIR DUCT ............................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
CHANGING AIR CLEANER FILTER ................... 14INTAKE MANIFOLD ................................................. 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 17
INSPECTION AFTER INSTALLATION ................ 18
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
OIL PAN AND OIL STRAINER ................................. 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
IGNITION COIL ......................................................... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSTALLATION ................................................... 26
SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 27
Removal and Installation ........................................ 27
REMOVAL ........................................................... 27
INSPECTION AFTER REMOVAL ....................... 27
INSTALLATION ................................................... 28
FUEL INJECTOR AND FUEL TUBE ........................ 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 30
INSPECTION AFTER INSTALLATION ................ 32
ROCKER COVER ..................................................... 33
Removal and Installation ........................................ 33
REMOVAL ........................................................... 33
INSTALLATION ................................................... 34
TIMING CHAIN .......................................................... 35
Removal and Installation ........................................ 35
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ....................... 38
INSTALLATION ................................................... 39
EM-2Revision: October 20052005 QX56 CAMSHAFT ............................................................... 43
Removal and Installation ........................................ 43
REMOVAL ........................................................... 43
INSPECTION AFTER REMOVAL ........................ 46
INSTALLATION .................................................... 48
Valve Clearance ...................................................... 51
INSPECTION ....................................................... 51
ADJUSTMENT .................................................... 53
OIL SEAL .................................................................. 55
Removal and Installation of Valve Oil Seal ............. 55
REMOVAL ........................................................... 55
INSTALLATION .................................................... 55
Removal and Installation of Front Oil Seal ............. 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 56
Removal and Installation of Rear Oil Seal .............. 56
REMOVAL ........................................................... 56
INSTALLATION .................................................... 57
CYLINDER HEAD ..................................................... 58
On-Vehicle Service ................................................. 58
CHECKING COMPRESSION PRESSURE ......... 58
Removal and Installation ........................................ 59
REMOVAL ........................................................... 59
INSPECTION AFTER REMOVAL ........................ 60
INSTALLATION .................................................... 60
Disassembly and Assembly .................................... 61
DISASSEMBLY ................................................... 61
ASSEMBLY ......................................................... 62
Inspection After Disassembly ................................. 63
CYLINDER HEAD DISTORTION ........................ 63
VALVE DIMENSIONS .......................................... 64
VALVE GUIDE CLEARANCE .............................. 65
VALVE GUIDE REPLACEMENT ......................... 65
VALVE SEAT CONTACT ..................................... 67
VALVE SEAT REPLACEMENT ........................... 67
VALVE SPRING SQUARENESS ......................... 68
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 68
ENGINE ASSEMBLY ................................................ 69
Removal and Installation ........................................ 69
REMOVAL ........................................................... 69
INSTALLATION .................................................... 72
INSPECTION AFTER INSTALLATION ................ 72
CYLINDER BLOCK ................................................... 73
Disassembly and Assembly .................................... 73
DISASSEMBLY ................................................... 74ASSEMBLY ..........................................................77
How to Select Piston and Bearing ..........................82
DESCRIPTION ....................................................82
HOW TO SELECT PISTON .................................83
HOW TO SELECT CONNECTING ROD BEAR-
ING .......................................................................84
HOW TO SELECT MAIN BEARING ....................85
Inspection After Disassembly ..................................89
CRANKSHAFT END PLAY ..................................89
CONNECTING ROD SIDE CLEARANCE ...........89
PISTON AND PISTON PIN CLEARANCE ...........89
PISTON RING SIDE CLEARANCE .....................90
PISTON RING END GAP ....................................90
CONNECTING ROD BEND AND TORSION .......91
CONNECTING ROD BEARING (BIG END) ........91
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) ...........................................91
CYLINDER BLOCK DISTORTION ......................92
MAIN BEARING HOUSING INSIDE DIAMETER ...93
PISTON TO CYLINDER BORE CLEARANCE ....93
CRANKSHAFT JOURNAL DIAMETER ...............94
CRANKSHAFT PIN DIAMETER ..........................95
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT .................................................................95
CRANKSHAFT RUNOUT ....................................95
CONNECTING ROD BEARING OIL CLEAR-
ANCE ...................................................................95
MAIN BEARING OIL CLEARANCE .....................96
CRUSH HEIGHT OF MAIN BEARING ................97
CRUSH HEIGHT OF CONNECTING ROD
BEARING .............................................................97
MAIN BEARING CAP BOLT DIAMETER .............97
CONNECTING ROD BOLT DIAMETER ..............98
SERVICE DATA AND SPECIFICATIONS (SDS) ......99
Standard and Limit ..................................................99
GENERAL SPECIFICATIONS .............................99
DRIVE BELTS ......................................................99
EXHAUST MANIFOLD ........................................99
CAMSHAFT AND CAMSHAFT BEARING ......... 100
CYLINDER HEAD .............................................. 102
CYLINDER BLOCK ............................................ 104
PISTON, PISTON RING AND PISTON PIN ...... 105
CONNECTING ROD .......................................... 105
CRANKSHAFT ................................................... 106
MAIN BEARING ................................................. 107
PRECAUTIONS
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Revision: October 20052005 QX56
PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00LLK
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00LLL
Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disconnecting and disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00LLM
When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and ReplacementEBS00LLN
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00LLO
Use torque wrench to tighten bolts or nuts to specification.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route when refilling after draining engine coolant.
Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure that there are no leaks at fuel line connections.
After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust
systems for leakage.
Parts Requiring Angular TighteningEBS00LLP
For final tightening of the following engine parts use Tool:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and lightly coated with engine oil. Tool number : KV10112100 (BT-8653-A)
EM-10Revision: October 2005
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
2005 QX56
Use the Chart Below to Help You Find the Cause of the Symptom.EBS00LLU
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not relatedLocation of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemRefer-
ence page Before
warm-
upAfter
warm-
upWhen
start-
ingWhen
idlingWhen
racingWhile
driv-
ing
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingC A — A B — Tappet noise Valve clearanceEM-51
Rattle C A — A B CCamshaft
bearing noiseCamshaft journal clear-
ance
Camshaft runoutEM-46EM-46
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil panSlap or
knock—A—B B—Piston pin
noisePiston and piston pin
clearance
Connecting rod bush-
ing clearanceEM-90
EM-92
Slap or
rapA——BBAPiston slap
noisePiston-to-bore clear-
ance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsionEM-94EM-90
EM-90
EM-91
Knock ABCBBBConnecting
rod bearing
noiseConnecting rod bush-
ing oil clearance (Small
end)
Connecting rod bear-
ing clearance (Big end)EM-92EM-91
Knock A B — A B CMain bearing
noiseMain bearing oil clear-
ance
Crankshaft runoutEM-96EM-95
Front of
engine
Chain case
cover
Front coverTa p p i n g
or tickingAA—BBBTiming chain
and chain
tensioner
noiseTiming chain cracks
and wear
Timing chain tensioner
operationEM-38
EM-35
Front of
engineSqueak-
ing or
fizzingAB—B—CDrive belts
(Sticking or
slipping)Drive belts deflection
EM-12
CreakingABABABDrive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakingAB—BABWater pum p
noiseWater pump operationCO-17,
"INSPEC-
TION
AFTER
REMOVA
L"