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CYLINDER HEADEM-95
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If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
Warm up engine thoroughly to check that there is no leak age of fuel, or any oil/fluids including engine oil and
engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
* Power steering fluid, brake fluid, etc. Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission /
transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage
MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Revision: 2010 May2011 QX56
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EM-96
< REMOVAL AND INSTALLATION >
OIL SEAL
OIL SEAL
FRONT OIL SEAL
FRONT OIL SEAL : Removal and InstallationINFOID:0000000006289574
REMOVAL
1. Remove the following parts:
Front under cover, using a power tool. Refer to EXT-25, "
Exploded View".
Drive belt: Refer to EM-20, "
Exploded View".
Cooling fan: Refer to CO-16, "
Exploded View".
2. Remove crankshaft pulley as per the following:
a. Remove rear plate cover. Refer to EM-54, "
Exploded View".
b. Set the ring gear stopper [SST: KV10120100 (J-47245)] (A) as shown in the figure.
c. Loosen crankshaft pulley bolt, and then pull crankshaft pulley with both hands to remove it.
CAUTION:
Never remove crankshaft pulley bolt. Keep loosened crank-
shaft pulley bolt in place to protect removed crankshaft pul-
ley from dropping.
3. Remove front oil seal using a suitable tool. CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1. Install front oil seal on front cover.
Apply new engine oil to both oil seal lip (A) and dust seal lip(B).
Install it so that each seal lip is oriented as shown in the figure. CAUTION:
Be careful not to scratch or make burrs on circumference
of oil seal.
Using a suitable drift [outer diameter: 56 mm (2.20 in)], press- fit oil seal until it becomes flush with front cover end face.
Check the garter spring is in position and seal lips are not inverted.
2. Install in the reverse order of removal.
REAR OIL SEAL
LBIA0455E
JPBIA3472ZZ
: Engine inside
: Engine outside
JPBIA0054ZZ
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OIL SEALEM-97
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REAR OIL SEAL : Removal and InstallationINFOID:0000000006289575
REMOVAL
1. Remove transmission assembly. Refer to
TM-205, "2WD : Exploded View" (2WD models) or TM-208,
"4WD : Exploded View" (4WD models).
2. Remove drive plate. Refer to EM-106, "
Exploded View".
3. Remove rear oil seal with a suitable tool. CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Install rear oil seal. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
Press in rear oil seal (1) to the position as shown in the figure.
Using a suitable drift [outer diameter 101 mm (3.98 in)], press-fit until the height of rear oil seal is level with the mounting surface.
Check the garter spring is in position and seal lips are not inverted. CAUTION:
Be careful not to damage crankshaft and cylinder block.
Press-fit straight and avoid cau sing burrs or tilting oil seal.
2. Install in the reverse order of removal after this step.
SBIA0360E
A : Oil seal lip
B : Dust seal lip : Engine inside
: Engine outside
JPBIA0054ZZ
B : Rear oil seal retainer rear end face
a : 0 - 0.5 mm (0 - 0.020 in)
JPBIA0152ZZ
SBIA0360E
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EM-98
< UNIT REMOVAL AND INSTALLATION >
ENGINE ASSEMBLY
UNIT REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Exploded ViewINFOID:0000000006289576
2WD models
JPBIA4257GB
1. Heat shield plate (RH) 2. Engine mounting insulator (RH) 3. Engine mounting bracket (RH)
4. Engine mounting bracket (LH) 5. Engine mounting insulator (LH) 6. Heat shield plate (LH)
7. Rear engine mounting cross member 8. Rear engine mounting insulator
Refer to GI-4, "
Components" for symbols in the figure.
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ENGINE ASSEMBLYEM-99
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4WD models
Removal and InstallationINFOID:0000000006289577
WARNING:
Situate the vehicle on a flat and solid surface.
Place chocks at the front
and back of rear wheels.
For engines not equipped with engi ne slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
Always be careful to work safely, and avo id forceful or uninstructed operations.
Never start working until exhaust system and engine coolant are cool enough.
If items or work required are not covered by th e engine section, refer to the applicable sections.
Always use the support poin t specified for lifting.
Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for
unavoidable reasons, support at r ear axle jacking point with transmi ssion jack or similar tool before
starting work, in preparat ion for the backward shift of the center of gravity.
For supporting points fo r lifting and jacking point at rear axle, refer to GI-32, "
Garage Jack and
Safety Stand".
NOTE:
When removing/installing only the engine mounting, the hold engine assembly as instructed bellow:
1. Remove hood assembly. Refer to DLK-215, "
Exploded View".
2. Remove the following components and related parts: Battery. Refer to PG-164, "
Exploded View".
Battery tray.
Power steering reservoir tank bracket. Refer to ST-54, "
Exploded View".
Air cleaner case assembly and air duct. Refer to EM-27, "
Exploded View".
JPBIA4256GB
1. Heat shield plate (RH) 2. Engine mounting insulator (RH) 3. Engine mounting bracket (RH)
4. Engine mounting bracket (LH) 5. Engine mounting insulator (LH) 6. Heat shield plate (LH)
7. Rear engine mounting cross member 8. Rear engine mounting insulator 9. Dynamic damper
Refer to GI-4, "
Components" for symbols in the figure.
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EM-100
< UNIT REMOVAL AND INSTALLATION >
ENGINE ASSEMBLY
3. Install engine slinger on both front right and front left sides of theengine.
4. Hoist the slinger to obtain room for engine assembly. CAUTION:
Use an engine lifter to prevent the engine slinger from fall-
ing and damaging the rocker cover.
REMOVAL
Outline
At first, remove the transmission and transfer assemb ly, steering gear and front final drive facing downward.
Then remove the engine.
Preparation
1. Remove engine cover. Refer to EM-25, "Exploded View".
2. Release fuel pressure. Refer to EC-153, "
Work Procedure".
3. Remove battery and tray. Refer to PG-164, "
Exploded View".
4. Remove the following components and related parts: Hood assembly. Refer to DLK-215, "
Exploded View".
Front under cover. Refer to EXT-25, "
Exploded View".
Front road wheel and tires. Refer to WT-64, "
Exploded View".
5. Drain engine oil. Refer to LU-8, "
Draining".
6. Drain engine coolant. Refer to CO-8, "
Draining".
CAUTION:
Perform this step when engine is cold.
Never spill engine coolant on drive belts.
7. Drain power steering fluid. Refer to ST-54, "
Exploded View".
Engine Room Front
1. Remove drive belt. Refer to EM-20, "Exploded View".
2. Remove fan shroud. Refer to CO-13, "
Exploded View".
3. Remove cooling fan and fan coupling. Refer to CO-16, "
Exploded View".
4. Remove radiator hoses (upper and lower).
5. Remove radiator.
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".
2. Remove protector A and B. Refer to SCS-32, "
FRONT TUBE ASSEMBLY : Exploded View".
3. Remove front suspension rear cross member. Refer to TM-205, "
2WD : Exploded View" (2WD models) or
TM-208, "
4WD : Exploded View" (4WD models).
4. Remove oil cooler. Refer to LU-11, "
Exploded View".
A : Engine front slinger (bank 2)
B : Engine front slinger (bank 1)
Slinger bolts:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
JPBIA3969ZZ
JPBIA2507ZZ
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ENGINE ASSEMBLYEM-101
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5. Remove A/T assembly. Refer to
TM-205, "2WD : Exploded View" (2WD models) or TM-208, "4WD :
Exploded View" (4WD models).
6. Remove steering gear assembly. Refer to ST-41, "
Exploded View".
7. Remove front final drive assembly. Refer to DLN-162, "
Exploded View".
8. Remove exhaust manifold. Refer to EM-40, "
Exploded View".
9. Remove alternator. Refer to CHG-25, "
Exploded View".
Engine Room LH
1. Remove air cleaner and air duct. Refer to EM-27, "Exploded View".
2. Remove A/C compressor. Refer to HA-30, "
Exploded View".
3. Disconnect fuel feed hose and EVAP hose. Refer to EM-43, "
Exploded View".
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
Engine Room RH
1. Remove power steering oil pump and reservoir tank. Refer to ST-48, "Exploded View".
2. Disconnect heater hose at heater core side, and fit a plug onto hose end to prevent engine coolant leak-
age.
3. Disconnect ground cable.
4. Disconnect all clips and connectors of the engine harness from vehicle side.
Removal Work
1. Install alternator bracket. Refer to CHG-25, "Exploded View".
Temporarily tighten mounting bolts.
2. Remove intake manifold. Refer to EM-30, "
Exploded View".
3. Remove starter motor. Refer to STR-17, "
Exploded View".
4. Install engine slingers.
5. Lift using a hoist and secure the engine in position.
6. Remove engine mounting bracket (LH, RH) and engine mounting insulator (LH, RH). Refer to EM-98,
"Exploded View".
7. Remove the engine from the vehi cle, avoid interference with the
vehicle body.
CAUTION:
Before and during lifting, always check that any har-
nesses are left connected.
Never damage engine mounti ng insulator and avoid oil/
grease smearing or spills onto engine mounting insulator.
A Engine front slinger (bank 2) B Engine rear slinger C Engine front slinger (bank 1)
Slinger bolts:
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
JPBIA3970ZZ
JPBIA3497ZZ
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EM-102
< UNIT REMOVAL AND INSTALLATION >
ENGINE ASSEMBLY
INSTALLATION
Install in the reverse order of removal.
CAUTION:
When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.Improper alignment caused by mi ssing dowels may cause vibration, oil leaks or
breakage of drivetrain components.
InspectionINFOID:0000000006289578
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluid leakage, lubricant leakage. Before starting engine, check oil/fluid levels includi ng engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-10, "
Fluids and Lubricants".
Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engi ne stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, che ck again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside chain tensioner drops af ter removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
Warm up engine thoroughly to check that there is no leak age of fuel, or any oil/fluids including engine oil and
engine coolant.
Bleed air from lines and hoses of applic able lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
*: Power steering fluid, brake fluid, etc. Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission /
transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage
MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
Revision: 2010 May2011 QX56