ENGINE ASSEMBLY
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CAUTION:
Be careful not to damage the drive plate. Especially
avoid deforming and damaging of the signal plate teeth
(circumference position).
Place the drive plate with the signal plate surface fac-
ing other than downward.
Keep magnetic materials away from the signal plate.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand.
–Remove the fuel tube and fuel injector assembly. Refer to EM-29, "REMOVAL" .
–Remove the intake manifold. Refer to EM-15, "REMOVAL" .
–Remove the ignition coil. Refer to EM-26, "REMOVAL" .
–Remove the rocker cover. Refer to EM-33, "REMOVAL" .
–Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
31. Remove the alternator. Refer to SC-27, "
REMOVAL" .
32. Remove the engine mounting insulator and bracket using power tool.
KBIA2491E
EM-72Revision: October 2005
ENGINE ASSEMBLY
2005 QX56
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.
Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-
etrain components.
INSPECTION AFTER INSTALLATION
Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are
lower than required quantity, fill to the specified level. Refer to MA-11, "
RECOMMENDED FLUIDS AND
LUBRICANTS" .
Use procedure below to check for fuel leakage.
Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel
leakage at the connection points.
Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids includ-
ing engine oil and engine coolant.
Bleed air from passages in lines and hoses, such as in cooling system.
After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
specified level if necessary.
Summary of the inspection items:
*Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
EM-74Revision: October 2005
CYLINDER BLOCK
2005 QX56
* Refer to GI-45, "Recommended Chemical Products and Sealants" .
DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note steps may be different.
1. Remove engine assembly and mount to engine stand. Refer to EM-69, "
REMOVAL" .
CAUTION:
Before removing the hanging chains, make sure engine stand is stable and there is no risk of over-
turning.
2. Drain engine oil. Refer to LU-8, "
Changing Engine Oil" .
3. Drain engine coolant by removing the cylinder block drain plugs
“A”, “B”, “C” and “D” as shown.
4. Remove the following components and associated parts (The parts referred to in step 1 are not included
here.)
Oil pan and oil strainer. Refer to EM-22, "REMOVAL" .
Crankshaft pulley, front cover and timing chain. Refer to EM-36, "REMOVAL" .
Camshaft. Refer to EM-43, "REMOVAL" .
Cylinder head. Refer to EM-59, "REMOVAL" .
5. Remove knock sensor.
CAUTION:
Carefully handle sensor, avoiding shocks.
6. Check connecting rod side clearance. Refer to EM-89, "
CONNECTING ROD SIDE CLEARANCE" .
7. Remove piston and connecting rod assembly as follows.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center.
b. Remove connecting rod cap.
1. Knock sensor sub-harness 2. Knock sensor 3. Cylinder block
4. Main bearing 5. Top ring 6. Second ring
7. Oil ring 8. Crankshaft key 9. Piston
10. Connecting rod 11. Snap ring 12. Piston pin
13. Connecting rod bearing 14. Connecting rod bearing cap 15. Main bearing cap
16. Thrust bearing 17. Main bearing 18. Crankshaft
19. Pilot converter 20. Thrust bearing 21. Side bolt
22. Drive plate 23. Reinforcement plate 24. Rear oil seal retainer
25. Rear oil seal 26. Transmission 27. O-ring
28. Crankshaft position sensor (POS) 29. Gasket 30. Cylinder block heater
31. Connector cap
WBIA0419E
CYLINDER BLOCK
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ASSEMBLY
1. Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove
any foreign material.
CAUTION:
Use goggles to protect your eyes.
2. Install each plug to the cylinder block (only screw-type plugs are
shown).
Apply liquid gasket.
Use Genuine Thread Sealant or equivalent. Refer to GI-
45, "Recommended Chemical Products and Sealants".
Replace copper washers with new ones.
Tighten each plug as specified below.
3. Install main bearings and thrust bearings.
a. Remove any dust, dirt, and oil on the bearing mating surfaces of
the cylinder block and the main bearing caps.
b. Install thrust bearings to both sides of the No. 3 journal housing
on the cylinder block and main bearing caps.
Install thrust bearings with the oil groove facing the crankshaft
arm (outside).
Install thrust bearings with a protrusion in the center on the
main bearing caps.
c. Install main bearings paying attention to the direction.
Install the one with oil holes onto the cylinder block and the
one without oil holes onto the main bearing cap.
Before installing bearings, apply engine oil to bearing surface
(inside). Do not apply oil to the back surface, but thoroughly
clean it.
When installing, align the bearing stopper to the notch.
Ensure the oil holes on the cylinder block and those on the
corresponding bearing are aligned.
4. Install pilot converter to the crankshaft using suitable tool.
5. Install crankshaft to the cylinder block.
While turning crankshaft by hand, make sure it turns
smoothly.
Part Washer Tightening torque
A Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)
B No 19.6 N·m (2.0 kg-m, 15 ft-lb)
C Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
D Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
WBIA0419E
PBIC0093E
PBIC0094E
EMP0569D
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CYLINDER BLOCK
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6. Install main bearing caps.
Align the identification number to the journal position to install.
Install it with the front mark (indicated by the arrow) facing the
front of engine.
Tap caps lightly to seat them in the installation position.
7. Follow the steps below to tighten each main bearing cap bolt.
a. Apply engine oil to threads and seating surfaces of bolts, and
tighten all bolts temporarily.
b. Measure tightening angle using Tool.
CAUTION:
Measure tightening angle using Tool. Do not measure visu-
ally.
Rotate crankshaft by hand after bolts are tightened. Check if it rotates smoothly.
Check crankshaft side clearance. Refer to EM-89, "CRANKSHAFT END PLAY" .
8. Install rear oil seal to the oil seal retainer.
CAUTION:
Do not damage or scratch outer circumference of oil seal.
Install new rear oil seal in the direction shown.
KBIA2533E
Main bearing cap bolts
in order of 1 to 10: 39.2 N·m (4.0 kg-m, 29 ft.-lb)
Main bearing cap sub
bolts in order of 11 to 20: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC0090E
Tool number : KV10112100 (BT-8653-A)
Main bearing cap bolts in
order of 1 to 10: 40°
Main bearing cap sub
bolts in order of 11 to 20: 30°
Side bolts in order of 21 to
30: 49 N·m (5.0 kg-m, 36 ft-lb)
WBIA0597E
SEM 71 5A
CYLINDER BLOCK
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Tap until flattened with the front edge of the rear oil seal
retainer using suitable tool.
Fit the rear oil seal until it is level with the rear end surface of
rear oil seal retainer.
9. Install rear oil seal retainer.
Apply liquid gasket thoroughly to rear oil seal retainer as
shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Products and Sealants".
Apply new engine oil on the lips of rear oil seal. Do not touch.
10. Install the piston to the connecting rod.
a. Install the snap ring to the grooves of the piston rear side.
Insert it fully into the groove to install.
b. Install the piston to the connecting rod.
Heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70 C° (140°
to 158 °F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod.
Assemble so that the front mark on the piston crown and the
oil holes and cylinder No. on the connecting rod are posi-
tioned as shown.
c. Install the snap ring to the grooves of the piston front side.
Insert it fully into the groove to install.
After installing, make sure connecting rod moves smoothly.
11. Install piston rings.
CAUTION:
Do not damage piston.
Position each ring with the gap as shown, referring to the pis-
ton front mark.
Install the second ring with the stamped surface facing
upward.
PBIC0097E
SBIA0391E
KBIA2534E
Stamped mark Second ring : 2N
PBIC0100E
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CYLINDER BLOCK
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12. Install the connecting rod bearings to the connecting rod and
connecting rod cap.
When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of the connecting rod to install.
Check that the oil holes on the connecting rod and those on
the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft
using Tool.
Position the crankshaft pin corresponding to the connecting
rod to be installed onto bottom dead center.
Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
Match the cylinder position with the cylinder No. on the con-
necting rod to install.
Install the piston with the front mark on the piston crown fac-
ing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from an interference of the connecting
rod big end.
14. Install connecting rod cap.
Match the stamped cylinder number marks on the connecting
rod with those on the cylinder cap to install.
15. Tighten connecting rod bolts using Tool.
Apply engine oil to threads and seats of connecting rod bolts.
After tightening bolts, make sure the crankshaft rotates
smoothly.
Check connecting rod side clearance. Refer to EM-89, "CON-
NECTING ROD SIDE CLEARANCE"
PBIC0266E
Tool number : EM03470000 (J-8037)
WBIA0626E
KBIA2536E
Tool number : KV10112100 (BT-8653-A
Connecting rod bolts
Step 1 : 19.6 N·m (1.5 kg-m, 11 ft-lb)
Step 2 : 90° clockwise
WBIA0627E
DRIVE SHAFT
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DRIVE SHAFTPFP:39100
Removal and InstallationEDS001XF
REMOVAL
1. Remove wheel and tire using power tool.
2. Remove engine under cover using power tool.
3. Remove ABS sensor harness from mount on knuckle.
CAUTION:
Do not pull on ABS sensor harness.
4. Without disassembling the hydraulic lines, remove brake caliper using power tool. Reposition it aside with
wire. Refer to BR-21, "
Removal and Installation of Brake Caliper Assembly and Disc Rotor" .
NOTE:
Avoid depressing brake pedal while brake caliper is removed.
5. Remove coil spring and shock absorber assembly using power tool. Refer to FSU-10, "
Removal and
Installation" .
6. Separate upper link ball joint stud from steering knuckle using
Tool.
Support lower link with jack.
7. Remove cotter pin, then remove drive shaft nut.
8. Remove drive shaft mounting bolts from front final drive.
9. Remove drive shaft from wheel hub and bearing assembly.
CAUTION:
When removing drive shaft, do not apply an excessive
angle to drive shaft joint. Also be careful not to exces-
sively extend slide joint.
INSPECTION AFTER REMOVAL
Move joint up, down, left, right, and in axial direction. Check for any rough movement or significant loose-
ness.
Check boot for cracks or other damage, and for grease leakage.
If damaged, disassemble drive shaft to verify damage, and
repair or replace as necessary.
1. Cotter pin 2. Drive shaft nut 3. Drive shaft
LDIA0159E
Tool number : ST29020001 (J-24319-01)
LEIA0095E
RAA0030D