FUEL PRESSUREEC-487
< ON-VEHICLE MAINTENANCE > [VK56DE]
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ON-VEHICLE MAINTENANCE
FUEL PRESSURE
Fuel Pressure CheckINFOID:0000000003771746
FUEL PRESSURE RELEASE
With CONSULT-IIl
1. Turn ignition switch ON.
2. Perform “FUEL PRESSURE RELEASE” in
“WORK SUPPORT” mode with CONSULT-IIl.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel pressure.
5. Turn ignition switch OFF.
Without CONSULT-IIl
1. Remove fuel pump fuse located in IPDM E/R.
2. Start engine.
3. After engine stalls, crank it two or three times to release all fuel pressure.
4. Turn ignition switch OFF.
5. Reinstall fuel pump fuse after servicing fuel system.
FUEL PRESSURE CHECK
CAUTION:
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
Be careful not to scratch or get the fuel hose conn ection area dirty when servicing, so that the quick
connector o-ring maintains sealability.
Use Fuel Pressure Gauge Kit J-44321 and Fuel Pr essure Adapter J-44321-6 to check fuel pressure.
Do not perform fuel pressure check with electrical system operating (i.e. lights, rear defog, A/C, etc.).
Fuel pressure gauge may indicate false readings du e to varying engine loads and changes in mani-
fold vacuum.
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pres-
sure cannot be completely released because JA 60 models do not have fuel return system.
1. Release fuel pressure to zero. Refer to "FUEL PRESSURE RELEASE".
2. Remove engine cover.
3. Remove fuel hose using Quick Connector Release J-45488. Refer to EM-40
.
Do not twist or kink fuel hose because it is plastic hose.
Do not remove fuel hose from quick connector.
Keep fuel hose connections clean.
4. Install Fuel Pressure Adapter J-44321-6 and Fuel Pressure Gauge (from kit J-44321) as shown in figure.
Do not distort or bend fuel rail tube when installing fuel pres-sure gauge adapter.
When reconnecting fuel hose, check the original fuel hose for damage and abnormality.
5. Turn ignition switch ON (reactivate fuel pump), and check for fuel leakage.
6. Start engine and check for fuel leakage.
7. Read the indication of fuel pressure gauge. During fuel pressure check, check for fuel leakage from fuel
connection every 3 minutes.
BBIA0380E
BBIA0390E
Revision: December 20092009 QX56
EM-4
< PRECAUTION >
PRECAUTIONS
5. When the repair work is completed, return the ignition switch to the ″LOCK ″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of a ll control units using CONSULT-III.
Precaution for Drain Engine CoolantINFOID:0000000005885850
Drain engine coolant when engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000005885851
• 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.
Precaution for Removal and DisassemblyINFOID:0000000005885852
• When instructed to use special service tools, use the s pecified 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 organi zed 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.
Precaution for Inspection, Repair and ReplacementINFOID:0000000005885853
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000005885854
• 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 theones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
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 s peed to check engine coolant, fuel, oil, and exhaust sys-
tems for leakage.
Parts Requiring Angular TighteningINFOID:0000000005885855
• 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)
Revision: December 20092009 QX56
TIMING CHAINEM-51
< ON-VEHICLE REPAIR >
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b. Apply liquid gasket as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
c. Check again that the timing alignment marks on the timing chain and on each sprocket are aligned. Then install the front cover.
d. Install the bolts in the numerical order shown.
e. After tightening, re-tighten to the specified torque. CAUTION:
Be sure to wipe off any excessive liquid gasket leaking onto
surface mating with oil pan.
11. Install the Intake valve timing control solenoid valve cover (RH) (A) and Intake valve timing control solenoid valve cover (LH) (B)
as follows:
• Cross mark that can not be seen after assembly (C)
a. Apply liquid gasket (D) as shown. Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
CAUTION:
The start and end of the appl ication of the liquid gasket
should be crossed at a position (C) that cannot be seen
after attaching the chain case cover.
b. Install the bolts and tighten them to specification in the numeri- cal order shown.
• A: Intake valve timing control solenoid valve cover (RH)
• B: Intake valve timing control solenoid valve cover (LH)
12. Install the crankshaft pulley. • Install the key of the crankshaft.
• Insert the pulley by lightly tapping it.
CAUTION:
Do not tap pulley on the side surface where th e belt is installed (outer circumference).
13. Tighten the crankshaft pulley bolt. • Lock the crankshaft using suitable tool, then tighten the bolt.
• Perform the following steps for angular tightening:
a. Apply engine oil onto the threaded parts of the bolt and seating area.
KBIA2517E
M6 × 50 mm (1.97 in) : No. 1, 20, 25, 26, 27
M6 × 80 mm (3.15 in) : No. 4, 5, 7
M6 × 20 mm (0.79 in) : Except the above
KBIA2478E
D : 2.6 - 3.6 mm (0.102 - 0.142 in) dia.
WBIA0800E
AWBIA0815ZZ
Revision: December 20092009 QX56
ENGINE UNITEM-87
< DISASSEMBLY AND ASSEMBLY >
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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 thefront 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 usin g 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-90, "
Inspection After Disassembly".
8. Install rear oil seal to rear oil seal retainer. CAUTION:
Do not damage or scratch ou ter 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
SEM715A
Revision: December 20092009 QX56
EXL-2
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure .....................................................................
31
HEADLAMP (HI) CIRCUIT ................................32
Description ........................................................... ...32
Component Function Check ...................................32
Diagnosis Procedure - Without Daytime Light Sys-
tem ..........................................................................
32
Diagnosis Procedure - With Daytime Light System
...
33
HEADLAMP (LO) CIRCUIT ...............................35
Description ........................................................... ...35
Component Function Check ...................................35
Diagnosis Procedure - Without Daytime Light Sys-
tem ..........................................................................
35
Diagnosis Procedure - With Daytime Light System
...
36
FRONT FOG LAMP CIRCUIT ...........................38
Description ........................................................... ...38
Component Function Check ...................................38
Diagnosis Procedure ..............................................38
PARKING LAMP CIRCUIT ................................40
Description ........................................................... ...40
Component Function Check ...................................40
Diagnosis Procedure - Without Daytime Light Sys-
tem ..........................................................................
40
Diagnosis Procedure - With Daytime Light System
...
42
TURN SIGNAL LAMP CIRCUIT ........................46
Description ........................................................... ...46
Component Function Check ...................................46
Diagnosis Procedure ..............................................46
OPTICAL SENSOR ...........................................49
Description ..............................................................49
Component Function Check ...................................49
Diagnosis Procedure ..............................................49
HEADLAMP AIMING SWITCH ..........................51
Description ........................................................... ...51
Diagnosis Procedure - Without Daytime Light Sys-
tem ..........................................................................
51
Diagnosis Procedure - With Daytime Light System
...
52
HEADLAMP .......................................................53
Wiring Diagram .................................................... ...53
DAYTIME LIGHT SYSTEM ................................57
Wiring Diagram .................................................... ...57
AUTO LIGHT SYSTEM ......................................64
Wiring Diagram .................................................... ...64
HEADLAMP AIMING SYSTEM (MANUAL) ......71
Wiring Diagram .................................................... ...71
FRONT FOG LAMP SYSTEM ...........................75
Wiring Diagram .................................................... ...75
TURN SIGNAL AND HAZARD WARNING
LAMP SYSTEM .............................................. ...
78
Wiring Diagram .................................................... ...78
PARKING, LICENSE PLATE AND TAIL
LAMPS SYSTEM ...............................................
85
Wiring Diagram .................................................... ...85
STOP LAMP ......................................................91
Wiring Diagram .................................................... ...91
BACK-UP LAMP ............................................ ...95
Wiring Diagram .................................................... ...95
TRAILER TOW .................................................100
Wiring Diagram .....................................................100
ECU DIAGNOSIS ......................................106
BCM (BODY CONTROL MODULE) ............... ..106
Reference Value .................................................. .106
Terminal Layout ....................................................108
Physical Values .....................................................108
Wiring Diagram .....................................................114
Fail Safe ...............................................................118
DTC Inspection Priority Chart .............................119
DTC Index ............................................................119
IPDM E/R (INTELLIGENT POWER DISTRI-
BUTION MODULE ENGINE ROOM) ................
121
Reference Value .................................................. .121
Terminal Layout ....................................................123
Physical Values .....................................................123
Wiring Diagram .....................................................128
Fail Safe ...............................................................131
DTC Index ............................................................133
SYMPTOM DIAGNOSIS ...........................134
EXTERIOR LIGHTING SYSTEM SYMPTOMS ..134
Symptom Table .................................................... .134
NORMAL OPERATING CONDITION ...............136
Description ........................................................... .136
BOTH SIDE HEADLAMPS DO NOT SWITCH
TO HIGH BEAM ................................................
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Description ........................................................... .137
Diagnosis Procedure .............................................137
BOTH SIDE HEADLAMPS (LO) ARE NOT
TURNED ON .....................................................
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Description ............................................................138
Diagnosis Procedure .............................................138
PARKING, LICENSE PLATE AND TAIL
LAMPS ARE NOT TURNED ON ......................
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Description ........................................................... .139
Revision: December 20092009 QX56
EXL-32
< COMPONENT DIAGNOSIS >
HEADLAMP (HI) CIRCUIT
HEADLAMP (HI) CIRCUIT
DescriptionINFOID:0000000005867521
The IPDM E/R (intelligent power distribution module engine room) controls the headlamp LH high and head-
lamp RH high relays based on inputs from the BCM via the CAN communication lines. When the headlamp LH
high and headlamp RH high relays are energized, power flows through fuse\
s 34 and 35, located in the IPDM
E/R. Power then flows to the front combination lamps to the headlamp high beam.
Component Function CheckINFOID:0000000003776179
1.CHECK HEADLAMP (HI) OPERATION
WITHOUT CONTULT-III
1. Start IPDM E/R auto active test. Refer to PCS-12, "
Diagnosis Description".
2. Check that the headlamp switches to the high beam. NOTE:
HI/LO is repeated 1 second each when usi ng the IPDM E/R auto active test.
CONSULT-III
1. Select "EXTERNAL LAMP" of IPDM E/R active test item.
2. With the test item operating, check that the headlamp switches to high beam.
Does the headlamp switch to high beam?
YES >> Headlamp (HI) circuit is normal.
NO >> Refer to EXL-32, "
Diagnosis Procedure - Without Daytime Light System", EXL-33, "Diagnosis
Procedure - With Daytime Light System".
Diagnosis Procedure - Wit hout Daytime Light SystemINFOID:0000000003776180
1.CHECK HEADLAMP (HI) FUSES
1. Turn the ignition switch OFF.
2. Check that the following fuses are not open.
Is the fuse open?
YES >> Repair the harness and replace the fuse.
NO >> GO TO 2.
2.CHECK HEADLAMP (HI) OUTPUT VOLTAGE
1. Turn the ignition switch OFF.
2. Disconnect the front combination lamp connector E11 or E107.
3. Turn the ignition switch ON.
4. Turn the high beam headlamps ON.
5. With the high beam headlamps ON, check the voltage between the combination lamp connector and ground.
Are the voltage readings as specified?
YES >> GO TO 4. HI : Headlamp switches to the high beam.
OFF : Headlamp OFF
Unit
LocationFuse No.Capacity
Headlamp HI (LH) IPDM E/R3510A
Headlamp HI (RH) IPDM E/R3410A
(+)
(−)Voltage
Connector Terminal
LH E11 6 GroundBattery voltage
RH E107 6
ALLIA0852ZZ
Revision: December 20092009 QX56
HEADLAMP (LO) CIRCUITEXL-35
< COMPONENT DIAGNOSIS >
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HEADLAMP (LO) CIRCUIT
DescriptionINFOID:0000000003776181
The IPDM E/R (intelligent power distribution modul e engine room) controls the headlamp low relay based on
inputs from the BCM via the CAN communication li nes. When the headlamp low relay is energized, power
flows through fuses 40 and 41, located in the IPDM E/R. Power then flows to the front combination lamps to
the headlamp low beam.
Component Function CheckINFOID:0000000003776182
1.CHECK HEADLAMP (LO) OPERATION
WITHOUT CONSULT-III
1. Start IPDM E/R auto active test. Refer to PCS-12, "
Diagnosis Description".
2. Check that the headlamp is turned ON. NOTE:
HI/LO is repeated 1 second each when using the IPDM E/R auto active test.
CONSULT-III
1. Select "EXTERNAL LAMP" of IPDM E/R active test item.
2. With the test items operating, c heck that the headlamp is turned ON.
Is the headlamp turned ON?
YES >> Headlamp (LO) is normal.
NO >> Refer to EXL-35, "
Diagnosis Procedure - Without Daytime Light System", EXL-36, "Diagnosis
Procedure - With Daytime Light System".
Diagnosis Procedure - Without Daytime Light SystemINFOID:0000000003776183
1.CHECK HEADLAMP (LO) FUSES
1. Turn the ignition switch OFF.
2. Check that the following fuses are not open.
Is the fuse open?
YES >> Repair the harness and replace the fuse.
NO >> GO TO 2.
2.CHECK HEADLAMP (LO) OUTPUT VOLTAGE
1. Turn the ignition switch OFF.
2. Disconnect the front combination lamp connector.
3. Turn the ignition switch ON.
4. Turn the low beam headlamps ON.
5. With the low beam headlamps ON, check the voltage between the combination lamp connector and ground.
Is voltage reading as specified?
YES >> GO TO 4. LO : Headlamp ON
OFF : Headlamp OFF
Unit
LocationFuse No.Capacity
Headlamp LO (LH) IPDM E/R4015A
Headlamp LO (RH) IPDM E/R4115A
(+)
(−)Voltage
Connector Terminal
LH E11 5
Ground Battery voltage
RH E107 5
ALLIA0855ZZ
Revision: December 20092009 QX56
EXL-40
< COMPONENT DIAGNOSIS >
PARKING LAMP CIRCUIT
PARKING LAMP CIRCUIT
DescriptionINFOID:0000000003776187
The IPDM E/R (intelligent power distribution module engine room) controls the tail lamp relay based on inputs
from the BCM via the CAN communication lines. When the tail lamp relay is energized, power flows through
fuse 37, located in the IPDM E/R. Power then flows to the front and rear combination lamps.
Component Function CheckINFOID:0000000003776188
1.CHECK PARKING LAMP OPERATION
WITHOUT CONSULT-III
1. Activate IPDM E/R auto active test. Refer to PCS-12, "
Diagnosis Description".
2. Check that the parking lamp is turned ON.
CONSULT-III
1. Select "EXTERNAL LAMP" of IPDM E/R active test item.
2. With operating the test items, check that the parking lamp is turned ON.
Is the parking lamp turned ON?
YES >> Parking lamp circuit is normal.
NO >> Refer to EXL-40, "
Diagnosis Procedure - Without Daytime Light System", EXL-42, "Diagnosis
Procedure - With Daytime Light System".
Diagnosis Procedure - Wit hout Daytime Light SystemINFOID:0000000003776189
1.CHECK PARKING LAMP FUSES
1. Turn the ignition switch OFF.
2. Check that the following fuses are not open.
Is the fuse open?
YES >> Repair the harness and replace the fuse.
NO >> GO TO 2.
2.CHECK TAIL LAMP RELAY OUTPUT (VOLTAGE)
1. Turn the ignition switch OFF.
2. Disconnect the front combination lamp connector, rear combination lamp connector and license plate
lamp connector.
3. Turn the ignition switch ON.
4. Turn the parking lamps ON.
5. With the parking lamps ON, check voltage between the front combination lamp connectors and ground.TAIL : Parking lamp ON
OFF : Parking lamp OFF
Unit
LocationFuse No.Capacity
Parking lamps IPDM E/R3710A
(+)
(−)V olt a ge
Connector Terminal
LH E11 3Ground Battery voltage
RH E107
ALLIA0857ZZ
Revision: December 20092009 QX56