DLN-252
< REMOVAL AND INSTALLATION >[REAR FINAL DRIVE: R230]
REAR FINAL DRIVE
REAR FINAL DRIVE BREATHER
Fill the rear final drive assembl
y with differential gear oil after installation. Refer to DLN-244, "Check-
ing Differential Gear Oil".
ALDIA0210GB
1. Rear final drive breather hose connector 2. Plastic clip 3. Rear final drive breather tube
4. Rear final drive assembly 5. Rear suspension member 6. Rear final drive breather hose
7. Parking brake cable 8. Exhaust pipe 9. Frame (LH)
10. Rear final drive breather hose frame
connector A. Close-up view Front
Revision: December 20092009 QX56
DLN-254
< DISASSEMBLY AND ASSEMBLY >[REAR FINAL DRIVE: R230]
REAR FINAL DRIVE
ASSEMBLY INSPECTION AND ADJUSTMENT
Drain the differential gear oil before inspection and adjustment. Refer to
DLN-244, "Changing Differential
Gear Oil".
Remove and install the carrier cover as neces sary for inspection and adjustment. Refer to DLN-249,
"Removal and Installation".
Total Preload Torque
1. Remove the side flanges if necessary. Refer to DLN-247, "Removal and Installation".
CAUTION:
The side flanges must removed in or der to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
4. Measure the total preload torque using Tool.
NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque
If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion
bearing preload torque first, then adjust the side bearing preload torque.
CAUTION:
Select a side bearing adjusting wash er for right and left individually.
Drive Gear Runout
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal
4. Drive pinion front bearing 5. Collapsible spacer 6. Drive pinion rear bearing
7. Drive pinion height adjusting washer 8. Drive pinion 9. Gear carrier
10. Drive gear 11. Pinion mate shaft 12. Lock pin
13. Pinion mate gear 14. Pinion mate thrust washer 15. Side gear
16. Side gear thrust washer 17. Differential case 18. Side bearing
19. Side bearing adjusting washer 20. Bearing cap 21. Carrier cover
22. Filler plug 23. Drain plug 24. Side oil seal
Tool number : ST3127S000 (J-25765-A)
Total preload torque
: Refer to DLN-270, "Inspection and Adjustment"
SPD884
If the total preload torque is greater than specification
On drive pinion bearings: R eplace the collapsible spacer.
On side bearings: Use thinner side b earing adjusting washers by the same
amount on each side. Refer to DLN-270, "Inspection and Adjust-
ment".
If the total preload torque is less than specification On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side b earing adjusting washers by the same
amount on each side. Refer to DLN-270, "Inspection and Ad-
justment".
Revision: December 20092009 QX56
REAR FINAL DRIVEDLN-257
< DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: R230]
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1. Rotate companion flange and check for runout on the outer face of the companion flange using suitable tool.
2. If the runout is outside of the runout limit, follow the procedure
below to adjust.
a. Rotate the companion flange on the drive pinion by 90 °, 180 °
and 270 ° while checking for the position where the runout is
minimum.
b. If the runout is still outside of the runout limit after the companion
flange has been rotated on the drive pinion, possible c ause could be an assembly malfunction of drive pin-
ion and drive pinion bearing or a malfunctioning drive pinion bearing.
c. If the runout is still outside of t he runout limit after repair of the assembly of drive pinion and drive pinion
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Side Flange
1. Drain the differential gear oil if necessary.
2. Remove the side flange using Tools.
3. Remove the side oil seal using suitable tool.
CAUTION:
Do not to damage gear carrier.
Differential Assembly
1. Remove the side flanges.
2. Remove the carrier cover bolts.
3. Remove the carrier cover bolts and separate the carrier coverfrom the gear carrier using Tool.
CAUTION:
Do not damage the mating surface.
Do not insert flat-bladed screw driver, this will damage the
mating surface. Runout limit : Refer to
DLN-270, "Inspection and
Adjustment"
WDIA0231E
Tool numbers A: KV40104100 ( — )
B: ST36230000 (J-25840-A)
WDIA0115E
LDIA0109E
Tool number : KV10111100 (J-37228)
WDIA0123E
Revision: December 20092009 QX56
DLN-266
< DISASSEMBLY AND ASSEMBLY >[REAR FINAL DRIVE: R230]
REAR FINAL DRIVE
10. Apply anti-corrosive oil to the threads of the drive pinion and the
seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using suitable tool (A),
and check the drive pinion bearing preload torque using Tool
(B).
CAUTION:
Do not reuse drive pinion lock nut.
Apply anti-corrosive oil to th e threads of the drive pinion
and the seating surface of the new drive pinion lock nut.
Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut
specified torque.
If the drive pinion bearing preload torque exceeds the specified value, replace collap sible spacer and tighten it
again to adjust. Do not lo osen drive pinion lock nut to
adjust the drive pinion bearing preload torque.
After adjustment, rotate dri ve pinion back and forth 2 to 3
times to check for unusual no ise, rotation malfunction,
and other malfunctions.
11. Check companion flange runout.
12. Install the differential case assembly.
Differential Assembly
1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly, or reinstall the old ones on
the side gears.
2. Install the side gears and side gear thrust washers into the dif- ferential case.
CAUTION:
Make sure that the circular clip is installed to side gears.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate
thrust washers by aligning them in diagonally opposite positions
and rotating them into the differential case.Tool number B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque
: Refer to DLN-270, "Inspection and Adjustment"
WDIA0379E
SDIA0193J
SDIA2025E
Revision: December 20092009 QX56
ON BOARD DIAGNOSTIC (OBD) SYSTEMEC-71
< FUNCTION DIAGNOSIS > [VK56DE]
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*: Leaving cooling fan OFF with CONSULT-III while engine is running may cause the engine to overheat.
DTC & SRT CONFIRMATION MODE
SRT STATUS Mode
For details, refer to
EC-456, "DTC Index".
SRT WORK SUPPORT Mode
This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status.
DTC WORK SUPPORT Mode
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
FUEL INJEC-
TION Engine: Return to the original
trouble condition
Change the amount of fuel injec-
tion using CONSULT-III. If trouble symptom disappears, see
CHECK ITEM.
Harness and connectors
Fuel injector
Air fuel ratio (A/F) sensor 1
IGNITION TIM-
ING Engine: Return to the original
trouble condition
Timing light: Set
Retard the ignition timing using
CONSULT-III. If trouble symptom disappears, see
CHECK ITEM.
Perform Idle Air Volume Learning.
POWER BAL-
ANCE Engine: After warming up, idle the
engine.
A/C switch: OFF
Selector lever: P or N
Cut off each injector signal one at a time using CONSULT-III. Engine runs rough or dies.
Harness and connectors
Compression
Fuel injector
Power transistor
Spark plug
Ignition coil
COOLING FAN* Ignition switch: ON
Turn the cooling fan HI and OFF
using CONSULT-III. Cooling fan moves and stops. Harness and connectors
Cooling fan motor
IPDM E/R
ENG COOLANT
TEMP Engine: Return to the original
trouble condition
Change the engine coolant tem- perature using CONSULT-III. If trouble symptom disappears, see
CHECK ITEM. Harness and connectors
Engine coolant temperature sen-
sor
Fuel injector
FUEL PUMP RE-
LAY Ignition switch: ON
(Engine stopped)
Turn the fuel pump relay ON and OFF using CONSULT-III and lis-
ten to operating sound. Fuel pump relay makes the operat-
ing sound.
Harness and connectors
Fuel pump relay
PURG VOL
CONT/V Engine: After warming up, run en-
gine at 1,500 rpm.
Change the EVAP canister purge
volume control solenoid valve
opening percent using CON-
SULT-III. Engine speed changes according to
the opening percent.
Harness and connectors
Solenoid valve
FUEL/T TEMP
SEN Change the fuel tank temperature using CONSULT-III.
VENT CON-
TROL/V Ignition switch: ON
(Engine stopped)
Turn solenoid valve ON and OFF with the CONSULT-III and listen
to operating sound. Solenoid valve makes an operating
sound.
Harness and connectors
Solenoid valve
V/T ASSIGN AN-
GLE Engine: Return to the original
trouble condition
Change intake valve timing using
CONSULT-III. If trouble symptom disappears, see
CHECK ITEM.
Harness and connectors
Intake valve timing control sole-
noid valve
ALTERNATOR
DUTY Engine: Idle
Change duty ratio using CON-
SULT-III. Battery voltage changes. Harness and connectors
IPDM E/R
Alternator
Revision: December 20092009 QX56
TROUBLE DIAGNOSIS - SPECIFICATION VALUEEC-77
< COMPONENT DIAGNOSIS > [VK56DE]
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Check “A/F ALPHA-B1”, “A/F ALPHA-B2” for approximat
ely 1 minute because they may fluctuate. It is NG
if the indication is out of the SP value even a little.
OK or NG
OK >> GO TO 17.
NG (Less than the SP value)>>GO TO 2.
NG (More than the SP value)>>GO TO 3.
2.CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “SPEC” of “DATA MONITOR” m ode, and make sure that the indication is within the
SP value.
OK or NG
OK >> GO TO 4.
NG (More than the SP value)>>GO TO 19.
3.CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “SPEC” of “DATA MONITOR” m ode, and make sure that the indication is within the
SP value.
OK or NG
OK >> GO TO 6.
NG (More than the SP value)>>GO TO 6.
NG (Less than the SP value)>>GO TO 25.
4.CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”
1. Stop the engine.
2. Disconnect PCV hose, and then plug it.
3. Start engine.
4. Select “A/F ALPHA-B1”, “A/F AL PHA-B2” in “SPEC” of “DATA MONITOR” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK >> GO TO 5.
NG >> GO TO 6.
5.CHANGE ENGINE OIL
1. Stop the engine.
2. Change engine oil. NOTE:
This symptom may occur when a large amount of gas oline is mixed with engine oil because of driving
conditions (such as when engine oil temperature does not rise enough since a journey distance is too
short during winter). The symptom will not be detect ed after changing engine oil or changing driving con-
dition.
>>INSPECTION END
6.CHECK FUEL PRESSURE
Check fuel pressure. (Refer to EC-487, "Fuel Pressure Check"
.)
OK or NG
OK >> GO TO 9.
NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-487, "Fuel Pressure Check"
.
GO TO 8.
NG (Fuel pressure is too low)>>GO TO 7.
7.DETECT MALFUNCTIONING PART
1. Check the following.
- Clogged and bent fuel hose and fuel tube
- Clogged fuel filter
- Fuel pump and its circuit (Refer to EC-487, "Fuel Pressure Check"
.)
2. If NG, repair or replace the malfunctioning part. (Refer to EC-487, "Fuel Pressure Check"
.)
If OK, replace fuel pressure regulator.
Revision: December 20092009 QX56
EC-78
< COMPONENT DIAGNOSIS >[VK56DE]
TROUBLE DIAGNOSIS - SPECIFICATION VALUE
>> GO TO 8.
8.CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”
1. Start engine.
2. Select “A/F ALPHA-B1”, “A/F AL PHA-B2” in “SPEC” of “DATA MONITOR” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK >> INSPECTION END
NG >> GO TO 9.
9.PERFORM POWER BALANCE TEST
1. Perform “POWER BALANCE” in “ACTIVE TEST” mode.
2. Make sure that the each cylinder produces a momentary engine speed drop.
OK or NG
OK >> GO TO 12.
NG >> GO TO 10.
10.DETECT MALFUNCTIONING PART
1. Check the following.
- Ignition coil and its circuit (Refer to EC-404, "Diagnosis Procedure"
.)
- Fuel injector and its circuit (Refer to EC-392, "Diagnosis Procedure"
.)
- Intake air leakage
- Low compression pressure (Refer to EM-23, "Checking Compression Pressure"
.)
2. If NG, repair or replace the malfunctioning part.
If OK, replace fuel injector. (It may be caus ed by leakage from fuel injector or clogging.)
>> GO TO 11.
11 .CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”
1. Start engine.
2. Select “A/F ALPHA-B1”, “A/F AL PHA-B2” in “SPEC” of “DATA MONITOR” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK >> INSPECTION END
NG >> GO TO 12.
12.CHECK A/F SENSOR 1 FUNCTION
Perform all DTC Confirmation Procedure related with A/F sensor 1.
For DTC P0130, P0150, refer to EC-136, "DTC Confirmation Procedure"
.
For DTC P0131, P0151, refer to EC-140, "DTC Confirmation Procedure"
.
For DTC P0132, P0132, refer to EC-143, "DTC Confirmation Procedure"
.
For DTC P0133, P0153, refer to EC-146, "DTC Confirmation Procedure"
.
For DTC P2A00, P2A03, refer to EC-377, "DTC Confirmation Procedure"
.
OK or NG
OK >> GO TO 15.
NG >> GO TO 13.
13.CHECK A/F SENSOR 1 CIRCUIT
Perform Diagnostic Procedure according to corresponding DTC.
>> GO TO 14.
14.CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”
1. Start engine.
2. Select “A/F ALPHA-B1”, “A/F AL PHA-B2” in “SPEC” of “DATA MONITOR” mode, and make sure that the
each indication is within the SP value.
OK or NG
Revision: December 20092009 QX56
TROUBLE DIAGNOSIS - SPECIFICATION VALUEEC-79
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OK >>
INSPECTION END
NG >> GO TO 15.
15.DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR
1. Stop the engine.
2. Disconnect ECM harness connector. Check pin term inal and connector for damage, and then reconnect it.
>> GO TO 16.
16.CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”
1. Start engine.
2. Select “A/F ALPHA-B1”, “A/F AL PHA-B2” in “SPEC” of “DATA MONITOR” mode, and make sure that the
each indication is within the SP value.
OK or NG
OK >> INSPECTION END
NG >> Detect malfunctioning part according to EC-475, "Symptom Matrix Chart"
.
17.CHECK “B/FUEL SCHDL”
Select “B/FUEL SCHDL” in “SPEC” of “DATA MONITOR” m ode, and make sure that the indication is within the
SP value.
OK or NG
OK >> INSPECTION END
NG (More than the SP value)>>GO TO 18.
NG (Less than the SP value)>>GO TO 25.
18.DETECT MALFUNCTIONING PART
1. Check for the cause of large engine friction. Refer to the following.
- Engine oil level is too high
- Engine oil viscosity
- Belt tension of power steering, alternator, A/C compressor, etc. is excessive
- Noise from engine
- Noise from transmission, etc.
2. Check for the cause of insufficient combustion. Refer to the following.
- Valve clearance malfunction
- Intake valve timing control function malfunction
- Camshaft sprocket installation malfunction, etc.
>> Repair or replace malfunctioning part, and then GO TO 30.
19.CHECK INTAKE SYSTEM
Check for the cause of uneven air flow through mass air flow sensor. Refer to the following.
Crushed air ducts
Malfunctioning seal of air cleaner element
Uneven dirt of air cleaner element
Improper specification of intake air system
OK or NG
OK >> GO TO 21.
NG >> Repair or replace malfunctioning part, and then GO TO 20.
20.CHECK “A/F ALPHA-B1”, “A/F ALPHA-B2”, AND “B/FUEL SCHDL”
Select “A/F ALPHA-B1”, “A/F ALPHA-B2”, and “B/F UEL SCHDL” in “SPEC” of “DATA MONITOR” mode, and
make sure that the each indication is within the SP value.
OK or NG
OK >> INSPECTION END
NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1”, “A /F ALPHA-B2” are less than the SP value)>>GO TO 21.
21.DISCONNECT AND RECONNECT MASS AIR FLOW SENSOR HARNESS CONNECTOR
1. Stop the engine.
Revision: December 20092009 QX56