DLN-232
< DISASSEMBLY AND ASSEMBLY >[FRONT FINAL DRIVE: M205]
FRONT FINAL DRIVE
10. Install side bearing adjusters into gear carrier.
11. Apply differential gear oil to the side bearings, and install the dif-
ferential case assembly with the side bearing outer races into
the gear carrier.
CAUTION:
Do not reuse side bearing ou ter race when replacing side
bearing inner race (replace as a set).
12. Install the side bearing caps with the matching marks aligned. NOTE:
Do not tighten at this step. This allows further tightening of side
bearing adjusters.
13. Tighten each side bearing adjuster alternately turning drive gear.
14. Check and adjust tooth contact, backlash, drive gear runout and total preload torque.
Recheck above items.
• After adjusting tooth contact and backlash secure side bearing
adjuster with screws and tighten side bearing cap bolt to the
specified torque. Refer to DLN-217, "
Disassembly and Assem-
bly".
15. Apply multi-purpose grease to the lips of the new side oil seal. Then drive the new side oil seal in evenly to
the gear carrier using suitable tool.
CAUTION:
• Do not reuse side oil seal.
• Do not incline the new side oil seal when installing.
• Apply multi-purpose grease to the lips of the new side oil seal.
SPD527
PDIA0700E
SDIA2265E
SDIA2263E
Revision: April 20092010 QX56
DLN-238
< PREPARATION >[REAR FINAL DRIVE: R230]
PREPARATION
PREPARATION
PREPARATION
Special Service ToolINFOID:0000000005148926
The actual shapes of Kent-Moore tool
s may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name Description
HT72400000
(—)
Slide hammer Removing differential case assembly
K V 1 0 1111 0 0
(J-37228)
Seal cutter Removing carrier cover
KV10112100
(BT-8653-A)
Angle wrench Tightening bolts for drive gear
KV38100200
(J-26233)
Drift Installing side oil seal
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
KV38100800
(J-25604-01)
Attachment Securing unit assembly
a: 541 mm (21.30 in)
b: 200 mm (7.87 in)
KV381054S0
(J-34286)
Puller Removing front oil seal
S-NT125
S-NT046
NT014
ZZA1143D
SDIA0267E
ZZA0601D
Revision: April 20092010 QX56
REAR FINAL DRIVEDLN-251
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R230]
C
EF
G H
I
J
K L
M A
B
DLN
N
O P
7. Place a suitable jack under the rear final drive assembly. CAUTION:
Do not place the jack on the carrier cover.
8. Remove the nuts and bolts and remove the rear final drive assembly.
CAUTION:
Secure rear final drive assembly to the jack while removing
it.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• When installing the breather hose make sure the pa inted marking on the metal end of breather hose
is to the front of the vehicle and there are no pinched or restricted areas on the breather hose
caused by folding or bend ing when installing it.
• When installing the breather hose insert the plastic end of the breather hose into the hole in the sus-
pension member.
WDIA0117E
Revision: April 20092010 QX56
EC-6
On Board Diagnosis Logic .....................................353
DTC Confirmation Procedure ................................353
Diagnosis Procedure .............................................353
Component Inspection ...........................................355
P2100, P2103 THROTTLE CONTROL MO-
TOR RELAY .....................................................
356
Component Description ....................................... ..356
On Board Diagnosis Logic .....................................356
DTC Confirmation Procedure ................................356
Diagnosis Procedure .............................................356
P2101 ELECTRIC THROTTLE CONTROL
FUNCTION .......................................................
359
Description ........................................................... ..359
On Board Diagnosis Logic .....................................359
DTC Confirmation Procedure ................................359
Diagnosis Procedure .............................................359
Component Inspection ...........................................362
P2118 THROTTLE CONTROL MOTOR ..........363
Component Description ....................................... ..363
On Board Diagnosis Logic .....................................363
DTC Confirmation Procedure ................................363
Diagnosis Procedure .............................................363
Component Inspection ...........................................364
P2119 ELECTRIC THROTTLE CONTROL
ACTUATOR .....................................................
365
Component Description ....................................... ..365
On Board Diagnosis Logic .....................................365
DTC Confirmation Procedure ................................365
Diagnosis Procedure .............................................366
P2122, P2123 APP SENSOR ..........................367
Component Description ....................................... ..367
On Board Diagnosis Logic .....................................367
DTC Confirmation Procedure ................................367
Diagnosis Procedure .............................................367
Component Inspection ...........................................369
P2127, P2128 APP SENSOR ..........................370
Component Description ....................................... ..370
On Board Diagnosis Logic .....................................370
DTC Confirmation Procedure ................................370
Diagnosis Procedure .............................................370
Component Inspection ...........................................373
P2135 TP SENSOR .........................................374
Component Description ....................................... ..374
On Board Diagnosis Logic .....................................374
DTC Confirmation Procedure ................................374
Diagnosis Procedure .............................................374
Component Inspection ...........................................377
P2138 APP SENSOR ......................................378
Component Description ....................................... ..378
On Board Diagnosis Logic .....................................378
DTC Confirmation Procedure ................................378
Diagnosis Procedure .............................................379
Component Inspection ......................................... .381
P2A00, P2A03 A/F SENSOR 1 ........................382
Component Description ....................................... .382
On Board Diagnosis Logic ....................................382
DTC Confirmation Procedure ................................382
Diagnosis Procedure .............................................383
ASCD BRAKE SWITCH ...................................388
Component Description ....................................... .388
Diagnosis Procedure .............................................388
Component Inspection ..........................................390
ASCD INDICATOR ...........................................391
Component Description ....................................... .391
Diagnosis Procedure .............................................391
COOLING FAN .................................................392
Diagnosis Procedure ............................................ .392
Component Inspection ..........................................392
ELECTRICAL LOAD SIGNAL ..........................394
Description ........................................................... .394
Diagnosis Procedure .............................................394
FUEL INJECTOR ..............................................396
Component Description ....................................... .396
Diagnosis Procedure .............................................396
Component Inspection ..........................................398
FUEL PUMP .....................................................399
Description ........................................................... .399
Diagnosis Procedure .............................................399
Component Inspection ..........................................402
ICC BRAKE SWITCH ..................................... ..403
Component Description ....................................... .403
Diagnosis Procedure .............................................403
Component Inspection ..........................................405
IGNITION SIGNAL ............................................407
Component Description ....................................... .407
Diagnosis Procedure .............................................407
Component Inspection ..........................................410
ON BOARD REFUELING VAPOR RECOV-
ERY (ORVR) .....................................................
412
System Description .............................................. .412
Diagnosis Procedure .............................................412
Component Inspection ..........................................414
POSITIVE CRANKCASE VENTILATION .........417
Description ........................................................... .417
Component Inspection ..........................................417
REFRIGERANT PRESSURE SENSOR ...........419
Component Description ....................................... .419
Diagnosis Procedure .............................................419
ECU DIAGNOSIS ......................................422
ECM ................................................................ ..422
Revision: April 20092010 QX56
DIAGNOSIS AND REPAIR WORKFLOWEC-11
< BASIC INSPECTION > [VK56DE]
C
D
E
F
G H
I
J
K L
M A
EC
NP
O
Are they within the SP value?
Yes >> GO TO 9.
No >> GO TO 8.
8.DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE
Detect malfunctioning part according to EC-75, "
Diagnosis Procedure".
Is malfunctioning part detected?
Yes >> GO TO 11.
No >> GO TO 9.
9.DETECT MALFUNCTIONING SYST EM BY SYMPTOM MATRIX CHART
Detect malfunctioning system according to EC-477, "
Symptom Matrix Chart" based on the confirmed symp-
tom in step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.
10.DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE
Inspect according to Diagnostic Procedure of the system.
NOTE:
The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection
is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI-
34, "Work Flow".
Is malfunctioning part detected?
Yes >> GO TO 11.
No >> Monitor input data from related sensors or check voltage of related ECM terminals using CON- SULT-III. Refer to EC-425, "
ECM Terminal and Reference Value", EC-422, "CONSULT-lll Refer-
ence Value in Data Monitor Mode".
11 .REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it, refer to EC-459, "
DTC Index".
>> GO TO 12.
12.FINAL CHECK
When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again,
and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
OK or NG
NG (DTC*1 is detected)>>GO TO 10.
NG (Symptom remains)>>GO TO 6.
OK >> 1. Before returning the vehicle to the cu stomer, make sure to erase unnecessary DTC*
1 in ECM
and TCM (Transmission Control Module). (Refer to EC-459, "
DTC Index" and TM-30, "OBD-
II Diagnostic Trouble Code (DTC)".)
2. If the completion of SRT is needed, drive vehicle under the specific driving pattern. Refer to EC-459, "
DTC Index".
3. INSPECTION END
*1: Include 1st trip DTC.
*2: Include 1st trip freeze frame data.
DIAGNOSTIC WORKSHEET
Description
Revision: April 20092010 QX56
ON BOARD DIAGNOSTIC (OBD) SYSTEMEC-41
< FUNCTION DIAGNOSIS > [VK56DE]
C
D
E
F
G H
I
J
K L
M A
EC
NP
O
ON BOARD DIAGNOSTIC (OBD) SYSTEM
IntroductionINFOID:0000000005149074
The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actua-
tors. The ECM also records various emission-related diagnostic information including:
The above information can be checked using procedures listed in the table below.
×
: Applicable —: Not applicable
*: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other.
The malfunction indicator lamp (MIL) on the instrument panel lights up when the same malfunction is detected
in two consecutive trips (Two trip detection logic) , or when the ECM enters fail-safe mode. (Refer to EC-456,
"Fail-Safe Chart".)
Two Trip Detection LogicINFOID:0000000005149075
When a malfunction is detected for the first time, 1st tr ip DTC and 1st trip Freeze Frame data are stored in the
ECM memory. The MIL will not light up at this stage. <1st trip>
If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in
the ECM memory, and the MIL lights up. The MIL lights up at the same time when the DTC is stored. <2nd
trip> The “trip” in the “Two Trip Detection Logic” m eans a driving mode in which self-diagnosis is performed
during vehicle operation. Specific on board diagnostic item s will cause the ECM to light up or blink the MIL,
and store DTC and Freeze Frame data, even in the 1st trip, as shown below.
× : Applicable —: Not applicable
When there is an open circuit on MIL circuit, the ECM c annot warn the driver by lighting up MIL when there is
malfunction on engine control system.
Emission-related diagnostic information Diagnostic service
Diagnostic Trouble Code (DTC) Service $03 of SAE J1979
Freeze Frame data Service $02 of SAE J1979
System Readiness Test (SRT) code Service $01 of SAE J1979
1st Trip Diagnostic Trou ble Code (1st Trip DTC) Service $07 of SAE J1979
1st Trip Freeze Frame data
Test values and Test limits Service $06 of SAE J1979
Calibration ID Service $09 of SAE J1979
DTC 1st trip DTC Freeze
Frame data 1st trip Freeze
Frame data SRT code SRT status Test value
CONSULT-III ×× × × × × —
GST ×× × —×××
ECM ××*— — — ×—
Items MIL
DTC1st trip DTC
1st trip 2nd trip
1st trip
displaying 2nd trip
displaying 1st trip
displaying 2nd trip
display- ing
Blinking Lighting
up Blinking Lighting
up
Misfire (Possible three way catalyst
damage) — DTC: P0300 - P0308 is
being detected ×
———— — ×—
Misfire (Possible three way catalyst
damage) — DTC: P0300 - P0308 is
being detected ——
×—— ×——
One trip detection diagnoses (Re-
fer to EC-459, "
DTC Index".) —
×—— ×———
Except above — — —×— ×× —
Revision: April 20092010 QX56
EC-44
< FUNCTION DIAGNOSIS >[VK56DE]
ON BOARD DIAGNOSTIC (OBD) SYSTEM
*: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the pr
iority for
models with CONSULT-III.
SRT Set Timing
SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is
done regardless of whether the result is OK or NG. T he set timing is different between OK and NG results and
is shown in the table below.
OK: Self-diagnosis is carried out and the result is OK.
NG: Self-diagnosis is carried out and the result is NG.
—: Self-diagnosis is not carried out.
When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will
indicate “CMPLT”. → Case 1 above
When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate
“CMPLT” at the time the respective se lf-diagnoses have at least one OK result. → Case 2 above
If one or more SRT related self-diagnoses showed NG resu lts in 2 consecutive cycles, the SRT will also indi-
cate “CMPLT”. → Case 3 above
The table above shows that the minimum number of cycl es for setting SRT as “INCMP” is one (1) for each
self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state
emissions inspection, it is unnecessary for each self-d iagnosis to be executed twice (Case 3) for the following
reasons:
• The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result.
• The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results.
• When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis
memory must be erased from ECM after repair.
EVAP SYSTEM 2 EVAP control system purge flow monitoring P0441
1 EVAP control system P0442
2 EVAP control system P0456
HO2S 2 Air fuel ratio (A/F) sensor 1 P0133, P0153
Heated oxygen sensor 2 P0137, P0157
Heated oxygen sensor 2 P0138, P0158
Heated oxygen sensor 2 P0139, P0159
SRT item
(CONSULT-III indication) Performance
Priority* Required self-diagnostic items to set the SRT to “CMPLT” Corresponding
DTC No.
Self-diagnosis result Example
Diagnosis Ignition cycle
← ON → OFF ← ON → OFF ← ON → OFF ← ON →
All OK Case 1 P0400OK (1) — (1)OK (2) — (2)
P0402 OK (1) — (1)— (1)OK (2)
P1402 OK (1) OK (2) — (2)— (2)
SRT of EGR “CMPLT” “CMPLT” “CMPLT” “CMPLT”
Case 2 P0400OK (1) — (1)— (1) — (1)
P0402 — (0)— (0)OK (1) — (1)
P1402 OK (1) OK (2) — (2)— (2)
SRT of EGR “INCMP” “INCMP” “CMPLT” “CMPLT”
NG exists Case 3 P0400OKOK ——
P0402 ——— —
P1402 NG—NG NG
(Consecutive NG)
(1st trip) DTC 1st trip DTC
—1st trip DTC DTC
(= MIL ON)
SRT of EGR “INCMP” “INCMP” “INCMP” “CMPLT”
Revision: April 20092010 QX56
EC-56
< FUNCTION DIAGNOSIS >[VK56DE]
ON BOARD DIAGNOSTIC (OBD) SYSTEM
When there is an open circuit on MIL circuit, the ECM c
annot warn the driver by lighting up MIL when there is
malfunction on engine control system.
Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as
NG for 5 trips, ECM warns the driver that engine cont rol system malfunctions and MIL circuit is open by means
of operating fail-safe function.
The fail-safe function also operates when above diagnos es except MIL circuit are detected and demands the
driver to repair the malfunction.
MIL Flashing Without DTC
When any SRT codes are not set, MIL may fl ash without DTC. For the details, refer to EC-459, "DTC Index".
HOW TO SWITCH DIAGNOSTIC TEST MODE
NOTE:
•It is better to count the ti me accurately with a clock.
• It is impossible to switch the di agnostic mode when an accelerator pedal position sensor circuit has
a malfunction.
• Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF.
How to Set Diagnostic Test Mode II (Self-diagnostic Results)
1. Confirm that accelerator pedal is fully releas ed, turn ignition switch ON and wait 3 seconds.
2. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
3. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MIL starts blinking.
NOTE:
Do not release the accelerator pedal for 10 seconds if MIL may start blinking on the halfway of this
10 seconds. This blinking is displaying SRT status and is continued for another 10 seconds. For
the details, refer to EC-459, "
DTC Index".
Diagnostic Test
ModeKEY and ENG.
Status Function
Explanation of Function
Mode I Ignition switch in
ON position
Engine stopped BULB CHECK
This function checks the MIL bulb for damage (blown, open
circuit, etc.).
If the MIL does not come on, check MIL circuit.
Engine running MALFUNCTION WARNING This is a usual driving condition. When a malfunction is de-
tected twice in two consecutive driving cycles (two trip de-
tection logic), the MIL will light up to inform the driver that a
malfunction has been detected.
The following malfunctions will light up or blink the MIL in
the 1st trip.
• Misfire (Possible three way catalyst damage)
• One trip detection diagnoses
Mode II Ignition switch in
ON position
Engine stopped SELF-DIAGNOSTIC
RESULTS
This function allows DTCs an
d 1st trip DTCs to be read.
Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut
Revision: April 20092010 QX56