EM-12Revision: October 2005
DRIVE BELTS
2005 QX56
DRIVE BELTSPFP:02117
Checking Drive BeltsEBS00LLW
WAR NIN G:
Be sure to perform when the engine is stopped.
1. Remove the air duct and resonator assembly when inspecting drive belt. Refer to EM-14
.
2. Make sure that the indicator (single line notch) of each auto tensioner is within the allowable working
range (between three line notches).
NOTE:
Check the auto tensioner indication when the engine is cold.
When the new drive belt is installed, the range should be as shown.
The indicator notch is located on the moving side of the auto tensioner.
3. Visually check entire belt for wear, damage or cracks.
4. If the indicator is out of allowable working range or belt is damaged, replace the belt.
Tension AdjustmentEBS00LLX
Belt tensioning is not necessary, as it is automatically adjusted by the auto tensioner.
Removal and InstallationEBS00LLY
DRIVE BELT
Removal
1. Remove the air duct and resonator assembly. Refer to EM-14 .
2. Install Tool on auto tensioner pulley bolt, move in the direction of
arrow (loosening direction of tensioner) as shown.
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
3. Remove the drive belt.
LBIA0391E
1. Drive belt 2. Power steering oil pump pulley 3. Generator pulley
4. Crankshaft pulley 5. A/C compressor 6. Idler pulley
7. Cooling fan pulley 8. Water pump pulley 9. Drive belt tensioner
Tool number : — (J-46535)
WBIA0537E
INTAKE MANIFOLD
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INSTALLATION
Installation is in the reverse order of removal.
Tighten the intake manifold bolts in numerical order as shown.
Install the EVAP canister purge control solenoid valve connector with it facing front of engine.
Tighten the electronic throttle control actuator bolts of the electric throttle control actuator equally and
diagonally in several steps.
After installation perform procedure in EM-18, "INSPECTION AFTER INSTALLATION" .
Install the water hose so that its overlap width for connection is between 27 mm (1.06 in) and 32 mm (1.26
in) (target: 27 mm 1.06 in).
Connecting Quick Connector of Fuel Tube
Install quick connector as follows (the steps are the same for quick connectors on both engine side and vehi-
cle side except for the quick connector cap).
1. Make sure no foreign substances are deposited in and around tube and quick connector, and they are not
damaged.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align center to insert quick connector straight into fuel tube.
Insert until the paint mark for engagement identification
(white) goes completely inside quick connector so that you
cannot see it from the straight side of the connected part. Use
a mirror to check this where it is not possible to view directly
from the straight side, such as quick connector on vehicle
side.
Insert fuel tube into quick connector until top spool is com-
pletely inside quick connector, and 2nd level spool exposes
right below quick connector on engine side.
CAUTION:
Hold "A" position in illustration when inserting fuel
tube into quick connector.
Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
Insert until you hear a “click” sound and actually feel
the engagement.
To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
4. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that
it does not come out from fuel tube.
NOTE:
Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
KBIA2462E
PBIC0017E
KBIA0272E
EM-20Revision: October 2005
EXHAUST MANIFOLD AND THREE WAY CATALYST
2005 QX56
c. Remove the air fuel ratio A/F sensors from both left and right
exhaust manifolds using Tool.
CAUTION:
Be careful not to damage the air fuel ratio A/F sensors
Discard any air fuel ratio A/F sensor which has been
dropped from a height of more than 0.5m (19.7 in) onto a
hard surface such as a concrete floor. Replace it with a
new one.
7. Remove the front cross bar.
8. Remove the exhaust manifold (left bank) following the steps
below.
a. Remove the exhaust front tube. Refer to EX-3, "
Removal and
Installation" .
b. Remove the exhaust manifold cover.
c. Loosen the nuts in reverse order of illustration using power tool.
d. Remove the exhaust studs from positions 2, 4, 6, 8 and remove
left exhaust manifold
9. Remove the exhaust manifold (right bank) following the steps
below.
a. Remove the exhaust front tube. Refer to EX-3, "
Removal and
Installation" .
b. Remove the oil level gauge guide. Refer to EM-22, "
OIL PAN
AND OIL STRAINER" .
c. Remove the exhaust manifold cover.
d. Loosen the nuts in reverse order of illustration using power tool.
e. Remove the exhaust studs from positions 2, 4, 6, 8 and remove right exhaust manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
Check the flatness of each exhaust manifold flange surface
using suitable tools.
If measurement exceeds the limit, replace the exhaust manifold.
INSTALLATION
Installation is in the reverse order of removal.
Install new exhaust manifold gasket with the top of the triangular
up mark on it facing up and its coated face (gray side) toward
the exhaust manifold side.Tool number : — (J-44626)
WBIA0630E
KBIA2464E
Flatness limit : 0.3 mm (0.012 in)
KBIA2504E
KBIA2553E
OIL PAN AND OIL STRAINER
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b. Tighten the oil pan (lower) bolts in numerical order as shown.
4. Install the oil pan drain plug.
5. Installation of the remaining components is in the reverse order of removal.
Do not fill the engine oil for at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil if necessary. Refer to LU-7, "OIL LEVEL" .
2. Start the engine, and check for leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again.
PBIC2595E
FUEL INJECTOR AND FUEL TUBE
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Handle O-ring with bare hands. Never wear gloves.
Lubricate new O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
Insert O-ring straight into fuel tube. Do not angle or twist it.
3. Install the fuel injector to the fuel tube using the following steps.
a. Insert new clip into clip mounting groove on the fuel injector.
Insert clip so that lug “A” of fuel injector matches notch “A” of
the clip.
CAUTION:
Do not reuse clip. Replace it with a new one.
Do not allow the clip to interfere with the O-ring. If
interference occurs, replace the O-ring.
b. Insert the fuel injector into the fuel tube with the clip attached.
Insert it while matching it to the axial center.
Insert fuel injector so that lug “B” of fuel tube matches notch
“B” of the clip.
Make sure that the fuel tube flange is securely fixed in the
flange fixing groove on the clip.
c. Make sure that installation is complete by checking that the fuel
injector does not rotate or come off.
Make sure that the protrusions of the fuel injectors are aligned
with the cutouts of the clips after installation.
4. Install the fuel tube and fuel injector assembly to the intake manifold.
CAUTION:
Do not let the tip of the injector nozzle come in contact with other parts.
Tighten fuel tube assembly bolts “a” to “b” in illustration in two
steps.
5. Install the fuel hose assembly.
Insert connectors straight, making sure that the axis is lined up with fuel tube side to prevent O-ring
from being damaged.
Tighten bolts evenly in several steps.
Make sure that there is no gap between the flange and fuel tube after tightening the bolts.
CAUTION:
Handle O-ring with bare hands. Do not wear gloves.Fuel tube side : Blue
Nozzle side : Brown
KBIA2507E
1st step : 12.8 N·m (1.3 kg-m, 9 ft-lb)
2nd step : 24.5 N·m (2.5 kg-m, 18 ft-lb)
KBIA2474E
EM-32Revision: October 2005
FUEL INJECTOR AND FUEL TUBE
2005 QX56
Lubricate O-ring with new engine oil.
Do not clean O-ring with solvent.
Make sure that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it
quickly into fuel tube.
Insert new O-ring straight into fuel tube. Do not twist it.
6. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
After installing the fuel tubes, make sure there are no fuel leaks at the connections using the following steps.
1. Apply fuel pressure to the fuel lines by turning ignition switch ON (with engine stopped). Then check for
fuel leaks at the connections.
NOTE:
Use mirrors for checking on hidden points.
2. Start the engine and rev it up and check for fuel leaks at the connections.
CAUTION:
Do not touch the engine immediately after stopping, as engine becomes extremely hot.
EM-38Revision: October 2005
TIMING CHAIN
2005 QX56
9. Remove the oil pump. Refer to LU-13, "Removal and Installation" .
10. Remove the chain tensioner on the left bank using the following steps.
NOTE:
To remove the timing chain and associated parts, start with those on the left bank. The procedure for
removing parts on the right bank is omitted because it is the same as that for the left bank.
a. Squeeze the return-proof clip ends using suitable tool and push
the plunger into the tensioner body.
b. Secure the plunger using stopper pin.
Stopper pin is made from hard wire approximately 1 mm (0.04
in) in diameter.
c. Remove the bolts and chain tensioner.
WAR NIN G:
Plunger, spring, and spring seat pop out when (squeezing)
return-proof clip without holding plunger head. It may
cause serious injuries. Always hold plunger head when
removing.
NOTE:
Stop the plunger in the fully extended position by using the
return-proof clip 1 if the stopper pin is removed.
Push the plunger 2 into the tensioner body while squeezing
the return-proof clip 1. Secure it using stopper pin 3.
11. Remove the chain tension guide and slack guide.
12. Remove the timing chain and crankshaft sprocket.
13. Loosen the camshaft sprocket bolts as shown and remove the
camshaft sprocket.
CAUTION:
To avoid interference between valves and pistons, do not
turn crankshaft or camshaft when timing chain is discon-
nected.
14. Repeat the same procedure to remove the right timing chain and
associated parts.
INSPECTION AFTER REMOVAL
Check for cracks and any excessive wear at link plates. Replace
chain if necessary.
In the same way as for the left bank, inspect the timing chain
and associated parts on the right bank.
KBIA2479E
KBIA2483E
KBIA2513E
PBIC0282E
EM-40Revision: October 2005
TIMING CHAIN
2005 QX56
3. Install the crankshaft sprockets for both banks.
Install each crankshaft sprocket so that its flange side (the
larger diameter side without teeth) faces in the direction
shown.
NOTE:
The same parts are used but facing directions are different.
4. Install the timing chains and associated parts.
Align the mating mark on each sprocket and the timing chain for installation.
CAUTION:
Before installing chain tensioner, it is possible to change the position of mating mark on tim-
ing chain and each sprocket. After the mating marks are aligned, keep them aligned by hold-
ing them by hand.
Install the slack guides and tension guides onto the correct side by checking the identification mark on
the surface.
Install the chain tensioner with the plunger locked in with the stopper pin.
CAUTION:
Before and after the installation of the chain tensioner, make sure that the mating mark on the
timing chain is not out of alignment.
After installing the chain tensioner, remove the stopper pin to release the tensioner. Make
sure the tensioner is released.
To avoid chain-link skipping of the timing chain, do not move crankshaft or camshafts until
the front cover is installed.
5. In the same way as for the right bank, install the timing chain and associated parts on the left side.
6. Install the oil pump.
7. Install the oil pump drive spacer as follows:
Install so that the front mark on the front edge of the oil pump
drive spacer faces the front of the engine.
Insert the oil pump drive spacer according to the directions of
the crankshaft key and the two flat surfaces of the oil pump
inner rotor.
If the positional relationship does not allow the insertion,
rotate the oil pump inner rotor to allow the oil pump drive
spacer to be inserted.
8. Install the front oil seal using suitable tool.
CAUTION:
Do not scratch or make burrs on the circumference of the
oil seal.
KBIA2515E
KBIA2490E
PBIC0059E