BRM-4
< PRECAUTION >
REPAIRING HIGH STRENGTH STEEL
PRECAUTION
REPAIRING HIGH STRENGTH STEEL
High Strength Steel (HSS)INFOID:0000000006248484
High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Read the following precautions when repairing HSS:
1. Additional points to consider
Tensile strength Major applicable parts 440 - 780 MPa Rear floor reinforcement
2nd seat mounting member assembly
Front seat mounting rear crossmember assembly
Front floor reinforcement
2nd crossmember (Lower)
Side radiator core support
Radiator core support main assembly
Front side member assembly
4th crossmember
2nd seat mounting crossmember
Rear side member
Rear crossmember
Inner side roof rail
Upper inner front pillar
Inner center pillar
Upper front pillar reinforcement
Lower center pillar brace
Front pillar brace
Outer sill reinforcement
Front roof rail
Rear roof rail
Radiator guard crossmember assembly
2nd crossmember assembly
2nd crossmember reinforcement
Front side member assembly
Front bound bumper bracket assembly
Lower front link mounting bracket assembly
Center side member assembly
Fuel tank protector assembly
Rear suspension mounting bracket assembly
Rear shock absorber bracket assembly
Rear side member assembly
Rear end gusset
Rear end crossmember assembly
980 - 1350 MPa Lower dash center reinforcement
(Lower dash Component part)
Inner sill
Rear seat crossmember
(2nd seat mounting crossmember component part)
Inner center pillar (Upper)
Upper outer center pillar reinforcement
(Lower center pillar brace component part)
Front bumper crossmember assembly
Revision: 2010 May2011 QX56
BRM-12
< PREPARATION >
BODY COMPONENT PARTS
NOTE:
For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
Tensile strength column shows the largest strength value of a part in the component part. No. Parts name
Tensile strength
(MPa) Both sided anti-corrosive
precoated steel sections
1. Hood Under 440×
2. Front fender (RH & LH) Under 440 ×
3. Inner side roof rail (RH & LH) 590 —
4. Upper inner front pillar (RH & LH) c. T=1.6 mm
(0.063 in)
980
caution—
5. Inner center pillar (RH & LH) d. T=1.6 mm
(0.063 in)
980
caution×
6. Center sill reinforcement assembly (RH & LH) Under 440 ×
7. Side body assembly (RH & LH) Refer to No.8 −13
8. Upper front pillar reinforcement (RH & LH) 590 —
9. Lower center pillar brace (RH & LH) e. T=1.8 mm
(0.071 in)
980
caution—
10. Front pillar brace (RH & LH) 590 —
11. Outer sill reinforcement (RH & LH) 590 ×
12. Outer front side body (RH & LH) Under 440 ×
13. Front fender bracket assembly (RH & LH) Under 440 ×
14. Outer sill (RH & LH) Under 440 ×
15. Front door assembly (RH & LH) 440 ×
16. Outer front door panel (RH & LH) Under 440 ×
17. Rear door assembly (RH & LH) 440 ×
18. Outer rear door panel (RH & LH) Under 440 ×
19. Back pillar reinforcement (RH & LH) Under 440 —
20. Inner back pillar (RH & LH) Under 440 —
21. Inner rear side roof rail (RH & LH) Under 440 —
22. Inner rear pillar (RH & LH) 590 —
23. Lower inner rear pillar (RH & LH)v Under 440 —
24. Side panel reinforcement (RH & LH) Under 440 —
25. Outer rear wheelhouse (RH & LH) Under 440 ×
26. Inner rear wheelhouse (RH & LH) Under 440 ×
27. Outer rear wheelhouse extension (RH & LH) Under 440 ×
28. Roof assembly Under 440 —
29. Front roof rail 440 —
30. Roof bow No.3 Under 440 —
31. Roof bow No.4 Under 440 —
32. Roof bow No.5 Under 440 —
33. Rear roof rail 440 —
34. Rear fender (RH & LH) Under 440 ×
35. Back pillar assembly (RH & LH) Under 440 —
36. Rear fender bracket (RH & LH) Under 440 —
37. Fuel filler lid Under 440 ×
38. Rear fender extension (RH & LH) Under 440 ×
39. Back door Under 440 ×
Revision: 2010 May2011 QX56
BRM-14
< PREPARATION >
BODY COMPONENT PARTS
NOTE:
For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
Tensile strength column shows the largest strength value of a part in the component part.
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. No. Parts name
Tensile strength
(MPa) Both sided anti-corrosive
precoated steel sections
1. Frame assembly Refer to No.2−36
2. Front bumper crossmember assembly T=1.8 mm
(0.071 in)
980
caution—
3. 2nd crossmember assembly 440 —
4. 2nd crossmember reinforcement (RH & LH) 440 —
5. 1st cab mounting bracket (RH & LH) Under 440 —
6. Front side member assembly (RH & LH) 540 —
7. Front suspension bracket assembly (RH & LH) Under 440 —
8. Engine mounting bracket assembly (RH & LH) Under 440 —
9. 2nd cab mounting bracket assembly (RH & LH) Under 440 —
10. 3way connector bracket assembly (RH & LH) Under 440 —
11. Piping bracket assembly (RH & LH) Under 440 —
12. Front bound bumper bracket assembly (RH & LH) 540 —
13. Lower front link mounting bracket assembly (RH & LH) 440 —
14. Diagonal member complete (RH & LH) 540 —
15. Rear engine mounting gusset assembly Under 440 —
16. Rear engine mounting member complete Under 440 —
17. Front fuel tank protector (RH & LH) Under 440 —
18. 3rd cab mounting bracket assembly (RH & LH) Under 440 —
19. Center side member assembly (RH & LH) 540 —
20. 6th crossmember assembly Under 440 —
21. Exhaust bracket (Front) Under 440 —
22. Fuel tank protector (RH & LH Rear) Under 440 —
23. Heat insulator bracket Under 440 —
24. Fuel tank protector assembly (RH & LH) 540 —
25. Rear suspension mounting bracket assembly (RH & LH) 540 —
26. 4th cab body mounting bracket assembly (RH & LH) Under 440 —
27. Rear brake hose bracket (RH & LH) Under 440 —
28. Rear shock absorber bracket assembly (RH & LH) 540 —
29. Rear side member assembly (RH & LH) 540 —
30. 5th cab body bracket (RH & LH) Under 440 —
31. 7th crossmember assembly Under 440 —
32. Exhaust bracket (Rear) Under 440 —
33. Spare wheel crossmember assembly Under 440 —
34. Front under cover bracket assembly Under 440 —
35. Rear end gusset (RH & LH) 440 —
36. Rear end crossmember assembly 540 —
Revision: 2010 May2011 QX56
CCS-72
< BASIC INSPECTION >[ICC]
LASER BEAM AIMING ADJUSTMENT
LASER BEAM AIMING ADJUSTMENT
DescriptionINFOID:0000000006224293
OUTLINE OF LASER BEAM AIMING ADJUSTMENT
Always adjust the laser beam aiming after removing and installing or replacing the ICC sensor.
CAUTION:
The system does not operate normally
unless the laser beam aiming adjustment is performed. Always
perform it.
1. Set the ICC target board [SST: KV99110100 (J-45718)] to the correct position in front of the vehicle.
2. Set the laser beam aiming mode (“LASER BEAM AD JUST” on “Work support”) with CONSULT-III, and
then perform the adjustment according to the displa y. (Manually turn the up-down direction adjusting
screw for vertical adjustment. ICC sensor adjusts the automatic aiming for the horizontal direction.)
CAUTIONARY POINT FOR LASER BEAM AIMING ADJUSTMENT
CAUTION:
For laser beam aiming adjustment, choose a level location where a view can be obtained without any
obstruction as far as 12 m (39 ft) or more in the forward direction.
Adjust laser beam aiming for 5 second s or more after starting engine.
Adjust the laser beam aiming with CONSULT-III. (The laser beam aiming cannot be adjusted without
CONSULT-III.)
Never enter the vehicle during laser beam aiming adjustment.
Never look directly into the laser beam sour ce (ICC sensor body window) during laser beam aiming
adjustment.
Laser beam aiming adjustment is performed at idle. At this time, turn the headlamps OFF.
Work Procedure (Preparation)INFOID:0000000006224294
1.ADVANCE PREPARATION FOR LASER BEAM AIMING ADJUSTMENT
1. Adjust all tire pressure to the specified value.
2. Empty the vehicle. (Remove any luggage from the passenger compartment, luggage room, etc.)
3. Shift the selector lever to “P” pos ition, and release the parking brake.
4. Fully fill the fuel tank, and then check that t he coolant and oils are filled up to correct level.
5. Clean off the ICC sensor body window with a soft cloth.
>> Go to CCS-72, "
Work Procedure (Setting The ICC Tar-
get Board)".
Work Procedure (Setting The ICC Target Board)INFOID:0000000006224295
DESCRIPTION
Accurate adjustment of the laser beam requires t hat the ICC target board be accurately positioned.
CAUTION:
If the laser beam is adjusted with the ICC target board in the incorrect position, the ICC system does
not function normally.
1.ICC TARGET BOARD HEIGHT ADJUSTMENT
1 : ICC sensor
JSOIA0372ZZ
Revision: 2010 May2011 QX56
CHG-8
< SYSTEM DESCRIPTION >
SYSTEM
scription
INFOID:0000000006274863
By performing the power generation voltage variable c ontrol, the engine load due to the power generation of
the alternator is reduced and fuel consumption is decreased.
NOTE:
When any malfunction is detected in the power generat ion voltage variable control system, the power genera-
tion is performed according to the characteristic of the IC voltage regulator of the alternator.
Revision: 2010 May2011 QX56
WATER INLET AND THERMOSTAT ASSEMBLYCO-21
< REMOVAL AND INSTALLATION >
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2. Remove front under cover with power tool. Refer to
EXT-25, "Exploded View".
3. Drain engine coolant from drain plugs on radiator and cylinder block. Refer to CO-8, "
Draining" and EM-
103, "Setting".
CAUTION:
Perform this step when engine is cold.
Never spill engine coolant on drive belts.
4. Disconnect radiator hose (upper and lower). Refer to CO-13, "
Exploded View".
5. Remove intake manifold. Refer to EM-30, "
Exploded View".
6. Remove fuel feed tube. Refer to EM-43, "
Exploded View".
7. Remove water hose, water connector, heater pipes and heater hoses.
8. Remove thermostat housing.
9. Remove water inlet and thermostat.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Be careful not to spill engine coolant over en gine room. Use rag to absorb engine coolant.
Thermostat
Install thermostat with the whole circumference of each flange part
(A) fit securely inside rubber ring (1).
Install thermostat with jiggle valve (A) facing upwards. The position deviation may be within the range of 20 degrees (b).
Water Connector and Heater Pipe
First apply a neutral detergent to O-rings, then quickly in sert the insertion parts of the water connector and
heater pipe into the installation holes.
InspectionINFOID:0000000006289674
INSPECTION AFTER REMOVAL
Check that valve in thermostat is co mpletely closing at normal temperature.
PBIC3315J
JPBIA2314ZZ
Revision: 2010 May2011 QX56
DAS-340
< BASIC INSPECTION >[LDW & LDP]
CAMERA AIMING ADJUSTMENT
CAMERA AIMING ADJUSTMENT
DescriptionINFOID:0000000006223734
Always adjust the camera aiming after removing
and installing or replacing the lane camera unit.
CAUTION:
Place the vehicle on level ground when th e camera aiming adjustment is operated.
Follow the CONSULT-III when performing the came ra aiming. (Camera aiming adjustment cannot be
operated without CONSULT-III.)
Work Procedure (Preparation)INFOID:0000000006223735
1.PERFORM SELF-DIAGNOSIS
Perform self-diagnosis of ADAS control unit and lane camera unit.
Is any DTC detected?
Except “C1B01”>>Perform diagnosis on the detected DTC and repair or replace the applicable item. Refer to
DAS-310, "
DTC Index" (ICC/ADAS) or DAS-316, "DTC Index" (LANE CAMERA).
“C1B01” or no DTC>>GO TO 2.
2.PREPARATION BEFORE CAMERA AIMING ADJUSTMENT
1. Perform pre-inspection for diagnosis. Refer to DAS-335, "
Inspection Procedure".
2. Adjust the tire pressure to the specified pressure value.
3. Maintain no-load in vehicle.
4. Check if coolant and engine oil are filled up to correct level and fuel tank is full.
5. Shift the selector lever to “P” position and release the parking brake.
6. Clean the windshield.
7. Completely clear off the instrument panel.
>> GO TO 3.
3. PREPARATION OF AIMING ADJUSTMENT JIG
Prepare the aiming adjustment jig according to the following procedure and the figure.
1. Print out the target mark attached in this service manual. Refer to DAS-343, "
Work Procedure (Target
Mark Sample)".
2. Stick a printed target mark on the board with a scotch tape or a piece of double-sided tape.
NOTE:
Use the board that peripheral area of the ta rget is monochrome such as a white-board.
Notice that the cross of the target is horizontal and vertical.
JPOIA0011ZZ
Revision: 2010 May2011 QX56
DLK-3
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Diagnosis Procedure ...........................................
....
98
B2423 AUTOMATIC BACK DOOR MOTOR
OPERATION TIME .............................................
99
DTC Logic ........................................................... ....99
Diagnosis Procedure ...............................................99
B2424 CLOSURE CONDITION ........................100
DTC Logic ........................................................... ..100
Diagnosis Procedure .............................................100
Component Inspection ..........................................101
B2425 AUTOMATIC BACK DOOR CONTROL
UNIT ..................................................................
103
DTC Logic ........................................................... ..103
Diagnosis Procedure .............................................103
B2621 INSIDE ANTENNA ................................104
DTC Logic ........................................................... ..104
Diagnosis Procedure .............................................104
B2622 INSIDE ANTENNA ................................106
DTC Logic ........................................................... ..106
Diagnosis Procedure .............................................106
B2623 INSIDE ANTENNA ................................108
DTC Logic ........................................................... ..108
Diagnosis Procedure .............................................108
B2626 OUTSIDE ANTENNA ............................110
DTC Logic ........................................................... ..110
Diagnosis Procedure .............................................110
B2627 OUTSIDE ANTENNA ............................112
DTC Logic ........................................................... ..112
Diagnosis Procedure .............................................112
B2628 OUTSIDE ANTENNA ............................114
DTC Logic ........................................................... ..114
Diagnosis Procedure .............................................114
POWER SUPPLY AND GROUND CIRCUIT ....116
AUTOMATIC BACK DOOR CONTROL UNIT ...... ..116
AUTOMATIC BACK DOOR CONTROL UNIT : Di-
agnosis Procedure ................................................
116
DOOR SWITCH ................................................117
Component Function Check .............................. ..117
Diagnosis Procedure .............................................117
Component Inspection ..........................................119
BACK DOOR SWITCH .....................................120
Component Function Check .............................. ..120
Diagnosis Procedure .............................................120
Component Inspection ..........................................121
DOOR LOCK AND UNLOCK SWITCH ............122
DRIVER SIDE ........................................................ ..122
DRIVER SIDE : Component Function Check ......122
DRIVER SIDE : Diagnosis Procedure ...................122
PASSENGER SIDE ..................................................122
PASSENGER SIDE :
Component Function Check .............................. ..
122
PASSENGER SIDE : Diagnosis Procedure ..........122
DOOR LOCK ACTUATOR ..............................123
DRIVER SIDE ......................................................... ..123
DRIVER SIDE : Component Function Check ......123
DRIVER SIDE : Diagnosis Procedure ...................123
PASSENGER SIDE ..................................................124
PASSENGER SIDE :
Component Function Check .............................. ..
124
PASSENGER SIDE : Diagnosis Procedure ..........124
REAR LH ................................................................ ..125
REAR LH : Component Function Check ..............125
REAR LH : Diagnosis Procedure ...........................125
REAR RH ............................................................... ..126
REAR RH : Component Function Check .............126
REAR RH : Diagnosis Procedure ..........................126
FUEL LID LOCK ACTUATOR ........................128
Component Function Check ................................128
Diagnosis Procedure .............................................128
UNLOCK SENSOR .........................................130
Component Function Check ................................130
Diagnosis Procedure .............................................130
Component Inspection ...........................................131
DOOR KEY CYLINDER SWITCH ...................132
Component Function Check ..................................132
Diagnosis Procedure .............................................132
Component Inspection ...........................................133
REMOTE KEYLESS ENTRY RECEIVER .......134
Component Function Check ................................134
Diagnosis Procedure .............................................134
DOOR REQUEST SWITCH ............................137
Component Function Check ................................137
Diagnosis Procedure .............................................137
Component Inspection ...........................................138
BACK DOOR REQUEST SWITCH .................139
Component Function Check ................................139
Diagnosis Procedure .............................................139
Component Inspection ...........................................140
BACK DOOR OPENER SWITCH ...................141
Component Function Check ................................141
Diagnosis Procedure .............................................141
Component Inspection ...........................................142
INTELLIGENT KEY WARNING BUZZER .......143
Component Function Check ................................143
Diagnosis Procedure .............................................143
Component Inspection ...........................................144
INTELLIGENT KEY .........................................145
Revision: 2010 May2011 QX56