EM-122
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Install connecting rod bearings (1) to connecting rod (2) and con-necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-107, "
Disassembly and Assembly" for the
tightening procedure.
Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner di ameter) – (Crankshaft pin journal diameter)
If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-125, "
Description".
Method of Using Plastigage
Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-107, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
Remove connecting rod bearing cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured va lue exceeds the limit is the
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
Install main bearings (3) to cylinder block (1) and main bearing cap (2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-107, "
Disassembly and Assembly" for the tightening
procedure.
Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
If the calculated value exceeds t he limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-125, "
Description".
Method of Using Plastigage
Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
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Standard and limit : Refer to EM-142, "ConnectingRodBearing".
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Standard and limit : Refer to EM-141, "MainBearing".
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Revision: 2010 May2011 QX56
EM-124
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Measure the outer diameters (A), (B) at two positions as shown in
the figure.
If reduction appears in (A) range, regard it (B).
If it exceeds the limit (large difference in dimensions), replace main bearing cap sub bolts with new one.
CONNECTING ROD BOLT OUTER DIAMETER
1. Measure the outer diameters [(a), (b) and (c)] at the position shown in the figure.
2. Obtain a mean value (d) of (a) and (b).
3. Subtract (c) from (d).
4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.
DRIVE PLATE
Check drive plate and signal plate (A) for deformation or damage.
CAUTION:
Never disassemble drive plate.
Never place drive plate with signal plate facing down.
When handling signal plate, take care not to damage or scratch it.
Handle signal plate in a manner that prevents it from becom-
ing magnetized.
If damage is found, replace drive plate.
OIL JET
Check nozzle for deformation and damage.
Blow compressed air from nozzle, and check for clogs.
Using a clean plastic stick, press check valve in oil je t relief valve. Check that valve moves smoothly with
proper reaction force.
If it is not satisfied, clean or replace oil jet.
c : 20 mm (0.79 in)
d : 15 mm (0.59 in)
e : 9 mm (0.35 in)
Limit [(B) – (A)] : 0.10 mm (0.0039 in)
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a : Value at the end of the smaller diameter of the bolt
b : Value at the end of the smaller diameter of the bolt [opposite side of (a)]
c : Value of the smallest diameter of the smaller of the bolt
Limit [(d) – (c)] : 0.08 mm (0.0032 in)JPBIA0262ZZ
B : Ring gear
: Engine front
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DIAGNOSIS SYSTEM (IPDM E/R)EXL-27
< SYSTEM DESCRIPTION > [XENON TYPE]
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DIAGNOSIS SYSTEM (IPDM E/R)
Diagnosis DescriptionINFOID:0000000006368066
AUTO ACTIVE TEST
Description
In auto active test, the IPDM E/R sends a drive signal to the following systems to check their operation.
Oil pressure warning lamp
Rear window defogger
Front wiper (LO, HI)
Parking lamp
License plate lamp
Tail lamp
Side marker lamp
Front fog lamp
Headlamp (LO, HI)
A/C compressor (magnet clutch)
Operation Procedure
CAUTION:
Never perform auto active test in the following conditions.
Engine is running.
CONSULT-III is connected.
1. Close the hood and lift the wiper arms from the windshield. (Prevent windshield damage due to wiper
operation)
NOTE:
When auto active test is performed with hood opened, sprinkle water on windshield beforehand.
2. Turn the ignition switch OFF.
3. Turn the ignition switch ON, and within 20 seconds, pr ess the driver door switch 10 times. Then turn the
ignition switch OFF.
CAUTION:
Close passenger door.
4. Turn the ignition switch ON within 10 seconds. Af ter that the horn sounds once and the auto active test
starts.
CAUTION:
Engine starts when ignition switch is turned ON while brake pedal is depressed.
5. The oil pressure warning lamp starts blinking when the auto active test starts.
6. After a series of the following operations is repeated 3 times, auto active test is completed.
NOTE:
When auto active test has to be cancelled halfw ay through test, turn the ignition switch OFF.
When auto active test is not activated, door swit ch may be the cause. Check door switch. Refer to DLK-117,
"ComponentFunctionCheck".
Inspection in Auto Active Test
When auto active test is actuated, the following operation sequence is repeated 3 times.
Operation
sequence Inspection location Operation
1 Oil pressure warning lamp Blinks continuously during operation of auto active test
2 Rear window defogger 10 seconds
3 Front wiper LO for 5 seconds → HI for 5 seconds
4 Parking lamp
License plate lamp
Tail lamp
Side marker lamp
Front fog lamp 10 seconds
Revision: 2010 May2011 QX56
HEADLAMP AIMING ADJUSTMENTEXL-121
< PERIODIC MAINTENANCE > [XENON TYPE]
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PERIODIC MAINTENANCE
HEADLAMP AIMING ADJUSTMENT
descriptionINFOID:0000000006213990
preparation before adjusting
NOTE:
for details, refer to the regulations in your own country.
perform aiming if the vehicle front body has been repaired and/or the headlamp assembly has been
replaced.
before performing aiming adjustment, check the following. adjust the tire pressure to the specification.
fill with fuel, engine coolant and each oil.
maintain the unloaded vehicle condition. (remove luggage from the passenger compartment and the lug- gage room.)
NOTE:
do not remove the temporary tire, jack and on-vehicle tool.
wipe out dirt on the headlamp.
CAUTION:
never use organic solvent (thinner, gasoline etc.)
ride alone on the driver seat.
aiming adjustment screw
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A. Headlamp RH HI /LO (UP/DOWN)
adjustment screw B. Headlamp LH HI/LO (UP/DOWN)
adjustment screw
: Vehicle center
Revision: 2010 May2011 QX56
FRONT FOG LAMP AIMING ADJUSTMENTEXL-123
< PERIODIC MAINTENANCE > [XENON TYPE]
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FRONT FOG LAMP AI MING ADJUSTMENT
DescriptionINFOID:0000000006213992
PREPARATION BEFORE ADJUSTING
NOTE:
For details, refer to the regulations in your own country.
Perform aiming if the vehicle front body has been repaired and/or the headlamp assembly has been
replaced.
Before performing aiming adjustm ent, check the following. Adjust the tire pressure to the specification.
Fill with fuel, engine coolant and each oil.
Maintain the unloaded vehicle condition. (Remove luggage from the passenger compartment and the trunk
room.)
NOTE:
Do not remove the temporary tire, jack and on-vehicle tool.
Wipe out dirt on the headlamp. CAUTION:
Never use organic solvent (thinner, gasoline etc.)
Ride alone on the driver seat.
AIMING ADJUSTMENT SCREW
Turn the aiming adjusting screw for adjustment.
For the position and direction of the adjusting screw, refer to the figure.
NOTE:
A screwdriver or hexagonal wrench [6 mm (0.24 in)] can be used
for adjustment.
Aiming Adjustment ProcedureINFOID:0000000006213993
1. Place the screen. NOTE:
Stop the vehicle facing the wall.
Place the board on a plain road vertically.
2. Face the vehicle with the screen. Maintain 10 m (32.8 ft) between the front fog lamp center and the
screen.
3. Start the engine. Turn the front fog lamp ON. NOTE:
Shut off the headlamp light with the board to pr event from illuminating the adjustment screen.
CAUTION:
Never cover the lens surface with a tape etc. The lens is made of resin.
4. Adjust the cutoff line height (A) with the aiming adjus tment screw so that the distance (X) between the hor-
izontal center line of front fog lamp (H) and (A) becomes 200 mm (7.87 in).
A: UP
B: DOWN
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PRECAUTIONSFSU-3
< PRECAUTION >
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5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of a ll control units using CONSULT-III.
Precaution for Procedure without Cowl Top CoverINFOID:0000000006271994
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precautions for SuspensionINFOID:0000000006225635
When installing rubber bushings, the final tightening mu st be carried out under unladen conditions with tires
on ground. Spilled oil might shorten the life of rubb er bushings. Be sure to wipe off any spilled oil.
- Unladen conditions mean that fuel, engine coolant and l ubricant are full. Spare tire, jack, hand tools and
mats are in designated positions.
After servicing suspension parts, be sure to check wheel alignment.
Self-lock nuts are not reusable. Always use new ones w hen installing. Since new self-lock nuts are pre-oiled,
tighten as they are.
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GI-1
GENERAL INFORMATION
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CONTENTS
GENERAL INFORMATION
HOW TO USE THIS MANU AL ......................3
HOW TO USE THIS MANUAL ....................... .....3
Description .......................................................... ......3
Terms ........................................................................3
Units ..........................................................................3
Contents ....................................................................3
Relation between Illustrations and Descriptions .......4
Components ..............................................................4
HOW TO FOLLOW TROUBLE DIAGNOSES .....6
Description ................................................................6
How to Follow Test Groups in Trouble Diagnosis ......6
Key to Symbols Signifying Measurements or Pro-
cedures ............................................................... ......
7
HOW TO READ WIRING DIAGRAMS ................9
Connector Symbols ............................................. ......9
Sample/Wiring Diagram -Example- .........................10
Connector Information .............................................12
ABBREVIATIONS .......................................... ....14
Abbreviation List .................................................. ....14
TIGHTENING TORQUE OF STANDARD
BOLTS ................................................................
19
Description .......................................................... ....19
Tightening Torque Table (New Standard Includ-
ed) ...........................................................................
19
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS ................................................
22
Recommended Chemical Products and Sealants ....22
VEHICLE INFORMATION ............................23
IDENTIFICATION INFORMATION ................. ....23
Model Variation ................................................... ....23
Information About Identification or Model Code ......23
Dimensions .............................................................25
Wheels & Tires ........................................................25
PRECAUTION ..............................................26
PRECAUTIONS .................................................26
Description ........................................................... ....26
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
26
Precautions For Xenon Headlamp Service .............26
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ...................................
27
Precaution for Procedure without Cowl Top Cover ....27
General Precautions ................................................27
Three Way Catalyst .................................................29
Multiport Fuel Injection System or Engine Control
System .....................................................................
29
Hoses ......................................................................29
Engine Oils ..............................................................30
Air Conditioning .......................................................31
Fuel ..........................................................................31
LIFTING POINT .................................................32
Pantograph Jack ......................................................32
Garage Jack and Safety Stand ................................32
2-Pole Lift ................................................................33
TOW TRUCK TOWING .....................................34
Tow Truck Towing ...................................................34
Vehicle Recovery (Freeing a Stuck Vehicle) ...........34
BASIC INSPECTION ...................................36
SERVICE INFORMATION FOR ELECTRICAL
INCIDENT ..........................................................
36
Work Flow ............................................................ ....36
Control Units and Electrical Parts ............................36
How to Check Terminal ...........................................37
Intermittent Incident .................................................40
Circuit Inspection .....................................................43
CONSULT-III/GST CHECKING SYSTEM .........48
Description ...............................................................48
CONSULT-III Function and System Application*1 ....48
Revision: 2010 May2011 QX56
ABBREVIATIONSGI-15
< HOW TO USE THIS MANUAL >
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ABBREVIATION DESCRIPTION E/T Exhaust temperature
EBD Electric brake force distribution EC Engine control
ECL Engine coolant level
ECM Engine control module ECT Engine coolant temperature
ECV Electrical control valve
EEPROM Electrically erasable programmable read only memory EFT Engine fuel temperature
EGR Exhaust gas recirculation
EGRT Exhaust gas recirculation temperature EGT Exhaust gas temperature
EOP Engine oil pressure EP Exhaust pressure
EPR Exhaust pressure regulator EPS Electronically controlled power steering
ESP Electronic stability program system
EVAP canister Evaporative emission canister EXC Exhaust control
ABBREVIATION DESCRIPTION FC Fan control
FCW Forward collision warning FIC Fuel injector controlFP Fuel pump
FR Front
FRP Fuel rail pressure FRT Fuel rail temperature
FTP Fuel tank pressure FTT Fuel tank temperature
ABBREVIATION DESCRIPTION GND GroundGPS Global positioning systemGST Generic scan tool
ABBREVIATION DESCRIPTION HBMC Hydraulic body-motion control systemHDD Hard disk drive
HO2S Heated oxygen sensor HOC Heated oxidation catalyst
Revision: 2010 May2011 QX56