DLK-218
< REMOVAL AND INSTALLATION >
HOOD
After installation, apply touch-up paint (the body color) onto the head of hood hinge mountingbolts and nuts.
HOOD HINGE
HOOD HINGE : Removal and InstallationINFOID:0000000006226065
REMOVAL
1. Remove hood assembly. Refer to DLK-215, "HOOD ASSEMBLY : Removal and Installation".
2. Remove front fender cover. Refer to EXT-21, "
Exploded View".
3. Remove front fender mounting bolt. DLK-222, "
Exploded View".
4. Remove hood hinge mounting bolts, and then remove hood hinge.
INSTALLATION
Note the following items, and install in the reverse order of removal.
CAUTION:
Before installation of hood hing e, apply anticorrosive agent onto the mounting surface of the vehicle
body.
After installation, apply touch-up paint (the body color) onto the head of the hinge mounting bolts
and nuts.
After installation, perform hood fitting adjustment. Refer to DLK-216, "
HOOD ASSEMBLY : Adjust-
ment".
HOOD STAY
HOOD STAY : Removal and InstallationINFOID:0000000006226066
REMOVAL
1. Support hood assembly with a proper material to prevent it from falling.
WARNING:
Bodily injury may occur if no proper material is holding the hood open when removing the hood
stay.
2. Remove the metal clip (3) located on the connection between the hood stay (1) and the stud ball (2) (hood side), by using a
flat-bladed screwdriver (A).
3. Disengage the stud ball from the hood stay (hood side).
4. Repeat the same operation to disengage the stud ball from the hood stay (body side), then remove the hood stay.
INSTALLATION
Install in the reverse order of removal.
HOOD STAY : Disposal INFOID:0000000006226067
1. Fix hood stay (1) using a vise (C).
2. Using hacksaw (A) slowly make 2 holes in the hood stay, innumerical order as shown in the figure.
CAUTION:
When cutting a hole on hood stay, always cover a hack-saw using a shop cloth (B) to avoid scattering metal frag-
ments or oil.
Wear eye protection (safety glasses).
Wear gloves.
JMKIA2255ZZ
JMKIA3336ZZ
Revision: 2010 May2011 QX56
RADIATOR CORE SUPPORTDLK-221
< REMOVAL AND INSTALLATION >
C
DE
F
G H
I
J
L
M A
B
DLK
N
O P
6. Disconnect all harness clips.
7. Remove hood lock assembly. Refer to DLK-238, "
Removal and Installation".
8. Remove fixing clips of air guide seal.
9. Remove mounting bolts, and then remove power steering oil cooler. Refer to ST-54, "
Exploded View".
CAUTION:
Put a wooden block (A) under the oil cooler (1) to prevent
the oil cooler from falling.
10. Remove radiator mounting bolts. Refer to CO-13, "
Removal and Installation".
11. Remove mounting bolts, and then radiator core support upper.
Installation
Note the following items, and then install in the reverse order of removal.
CAUTION:
If aluminum plate remains to the body side when removing radiator core support upper, be sure to
pinch aluminum plate between radiator core support upper and hoodledge upper when installing
radiator core support upper, for preventing electric corrosion.
When installing radiator core support upper, be careful not to damage the painted surface.
RADIATOR CORE SUPPORT LOWER
Removal
1. Remove front bumper fascia, bumper retainer and Bumper retainer bracket CTR. Refer to EXT-13,
"Removal and Installation".
2. Remove fixing clips, and then air guide seal and radiator side seal.
3. Remove ambient sensor. Refer to HAC-147, "
Removal and Installation".
4. Remove crash zone sensor. Refer to SR-22, "
Removal and Installation".
5. Remove all harness clips.
6. Remove mounting bolts, and then remove radiator core support main.
Installation
Install in the reverse order of removal.
JMKIA5480ZZ
Revision: 2010 May2011 QX56
DLK-234
< REMOVAL AND INSTALLATION >
BACK DOOR
BACK DOOR ASSEMBLY : Adjustment
INFOID:0000000006226088
Check the clearance and the surface height between back door and each part by visually and touching.
If the clearance and the surface height are out of spec ification, adjust them according to the procedures
shown below.
1. Back door assembly 2. Back door hinge 3. Back door striker
4. TORX bolt 5. Bumper rubber 6. Roof
7. Rear roof spoiler 8. Body side outer 9. Back door glass
10. Rear combination lamp 11. Back up lamp 12. Rear bumper fascia
Refer to GI-4, "
Components" for symbols in the figure.
JMKIA5483GB
Revision: 2010 May2011 QX56
BACK DOORDLK-235
< REMOVAL AND INSTALLATION >
C
DE
F
G H
I
J
L
M A
B
DLK
N
O P
Unit: mm (in)
1. Remove luggage rear plate mask. Refer to INT-35, "LUGGAGE REAR PLATE : Removal and Installation".
2. Loosen back door striker mounting bolts.
3. Loosen back door hinge mounting nuts (back door side).
4. Loosen bumper rubber (side and lower).
5. Lift up back door approximately 100 – 150 mm (3.937 – 5.906 in) height then close it lightly and check that
it is engaged firmly with back door closed.
6. Check the clearance and surface height.
7. Finally tighten back door hinge, bumper rubber, and back door striker.
8. Install luggage rear plate mask. Refer to INT-35, "
LUGGAGE REAR PLATE : Removal and Installation".
BACK DOOR STRIKER ADJUSTMENT
Adjust back door striker so that i becomes parallel with back door lock insertion direction.
BACK DOOR STRIKER
BACK DOOR STRIKER : Removal and InstallationINFOID:0000000006226089
REMOVAL
1. Remove luggage rear plate. Refer to INT-35, "LUGGAGE REAR PLATE : Removal and Installation".
2. Remove mounting TORX bolts, and then remove back door striker.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
Check back door open/close ope ration after installation.
When removing and installing b ack door striker, check to perform th e fitting adjustment. Refer to
DLK-234, "
BACK DOOR ASSEMBLY : Adjustment".
Portion Standard
Difference
(LH/RH, MAX)
Roof – Rear roof spoiler A – A H Clearance
5.0 – 9.0
(0.197 – 0.354) —
I Surface height (
− 1.0) – (+3.0)
[( −0.039) – (+0.118)] —
Body side outer panel –
Rear roof spoiler B – B J Clearance 3.8 – 7.8
(0.150 – 0.307) ≤
2.0
(0.079)
Body side outer panel –
Back door glass C – CK Clearance
3.0 – 7.0
(0.118 – 0.276) ≤
2.0
(0.079)
L Surface height 0.0 – 4.0
(0.000 – 0.157) ≤
2.0
(0.079)
Body side outer panel –
Back door D – DM Clearance
4.0 – 6.0
(0.157 – 0.236) ≤
1.0
(0.039)
N Surface height (
− 1.0) – (+1.0)
[( −0.039) – (+0.039)] ≤
1.0
(0.039)
Rear combination lamp
– Back up lamp E – EO Clearance
2.5 – 7.5
(0.098 – 0.295) ≤
2.2
(0.087)
P Surface height (
− 2.2) – (+2.2)
[( −0.087) – (+0.087)] ≤
2.2
(0.087)
Rear bumper fascia –
Back door F – F Q Clearance 2.9 – 7.1
(0.114 – 0.280) ≤
2.1
(0.083)
Rear bumper fascia –
Back door G – G R Clearance 4.0 – 8.0
(0.157 – 0.315) —
Revision: 2010 May2011 QX56
BACK DOORDLK-237
< REMOVAL AND INSTALLATION >
C
DE
F
G H
I
J
L
M A
B
DLK
N
O P
BACK DOOR STAY : Disposal INFOID:0000000006226092
1. Fix back door stay (1) using a vise (C).
2. Using hacksaw (A) slowly make 2 holes in the back door stay, in numerical order as shown in the figure.
CAUTION:
When cutting a hole on back door stay, always cover ahacksaw using a shop cloth (B) to avoid scattering metal
fragments or oil.
Wear eye protection (safety glasses).
Wear gloves.
BACK DOOR WEATHER-STRIP
BACK DOOR WEATHER-STRIP : Removal and InstallationINFOID:0000000006226093
REMOVAL
1. Remove stud ball of back door support rod from back door assembly. Refer to DLK-247, "BACK DOOR
SUPPORT ROD : Removal and Installation".
2. Pull up and remove engagement with body from weather-strip joint. CAUTION:
Never pull strongly on weather-strip.
INSTALLATION
1. Working from the upper section, align weather-strip mark with vehicle center position mark and install
weather-strip onto the vehicle.
2. For the lower section, align weather-str ip seam with center of back door striker.
3. Pull weather-strip gently to ensure that there is no loose section. NOTE:
Check that weather-strip is fit tightly at each corner and luggage rear plate.
4. Install mounting bolts of power back door drive assembly (Back door side).
5. Install stud ball of back door support rod to back door assembly. Refer to DLK-247, "
BACK DOOR SUP-
PORT ROD : Removal and Installation".
JMKIA3336ZZ
A: 20 mm (0.787 in)
B: Cut at the groove.
JMKIA3609ZZ
Revision: 2010 May2011 QX56
DLK-252
< REMOVAL AND INSTALLATION >
CAB MOUNTING INSULATOR
Drain brake fluid from brake line. Refer to BR-10, "Draining".
Release fuel pressure. Refer to EC-153, "
Work Procedure".
Disconnect both battery cables. Refer to PG-164, "
Removal and Installation".
Drain engine coolant from radiator. Refer to CO-8, "
Draining".
Discharge refrigerant from A/C circuit. Refer to HA-20, "
Recycle Refrigerant".
Drain power steering fluid from reservoir tank.
4. Remove parts relating to connection of body assembly and frame assembly. Tire and wheel: Refer to WT-64, "
Removal and Installation" (with TPMS).
Front fender protector (LH and RH): Refer to EXT-23, "
FENDER PROTECTOR : Removal and Installa-
tion".
Front bumper: Refer to EXT-13, "
Removal and Installation".
Radiator core support upper: Refer to DLK-220, "
Removal and Installation".
Fan shroud: Refer to CO-16, "
Removal and Installation".
Battery and battery case: Refer to PG-164, "
Removal and Installation".
Air cleaner case (upper and lower): Refer to EM-27, "
Removal and Installation".
Engine cover: Refer to EM-25, "
Removal and Installation".
Rear wheel house protector (LH and RH): EXT-24, "
REAR WHEEL HOUSE PROTECTOR : Removal
and Installation".
Rear bumper: Refer to EXT-17, "
Removal and Installation".
Fuel filler tube: Remove to FL-8, "
Exploded View".
Spare tire
Towing hook bracket.
5. Separate parts relating to connection of body assembly and frame assembly. Vehicle front
Disconnect ICC sensor connector. (models with ICC) Refer to CCS-176, "
Removal and Installation".
Remove radiator upper hose and radiator lower hose from radiator assembly. Refer to CO-13,
"Exploded View".
Remove A/T fluid cooler hose B and A/T fluid cooler hose E from A/T fluid cooler tubes. Refer to TM-
202, "Exploded View".
Remove power steering return hose from oil cooler, and then power steering return hose clamp bolt from frame assembly. Refer to ST-54, "
Exploded View".
Remove power steering suction hose from reservoir tank. Refer to ST-54, "
Exploded View".
CAUTION:
Never spill power steering fluid in engine room.
Remove A/C low-presser flexible hose from A/C low-presser pipe. Refer to HA-35, "
LOW-PRESSURE
FLEXIBLE HOSE : Removal and Installation".
Remove A/C hi-presser flexible hose from condenser. Refer to HA-34, "
HIGH-PRESSURE FLEXIBLE
HOSE : Removal and Installation".
Remove all engine Control Harness connectors, har ness clips and others that are connected to the
body assembly side of the engine room. (engine room LH and RH side). Refer to PG-148, "
Engine Con-
trol Harness".
NOTE:
Separate harness connectors from ECM (engine control module). Refer to EC-10, "
General Precau-
tions".
CAUTION:
When pulling out harnesses, never damage harnesses or connectors.
After temporarily securing connectors, cover th em with vinyl or similar material to protect
against adhesion of foreign materials.
Disconnect engine room harness connectors and remo ve harness clips from engine assembly (engine
RH side). Refer to PG-146, "
Engine Room Harness".
Remove heater hoses from front water outlet tube (engine room RH side). Refer to HA-33, "
Exploded
View".
Disconnect front wheel sensor connectors (LH and RH). Refer to BRC-134, "
FRONT WHEEL SENSOR
: Exploded View".
Disconnect fuel feed tube and EVAP hos e (front wheel well LH side).
Remove steering lower shaft from steering gear side assembly. Refer to ST-37, "
Removal and Installa-
tion"
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and
steering gear assembly.
Revision: 2010 May2011 QX56
CAB MOUNTING INSULATORDLK-253
< REMOVAL AND INSTALLATION >
C
DE
F
G H
I
J
L
M A
B
DLK
N
O P
Remove brake tube from connector (front wheel well LH and RH side). Refer to BR-22, "FRONT :
Exploded View"
Vehicle center side
Remove A/T control cable from manual lever. Refer to TM-178, "
Removal and Installation".
Separate parking brake rear cable (LH and RH) from parking brake front cable. Refer to PB-5, "
Removal
and Installation".
Remove engine room harness connector (frame assembly RH center side). Refer to PG-146, "
Engine
Room Harness"
- Remove harness connector protector.
- Disconnect chassis harness connector from engine room harness connector.
- Remove harness bracket bolt, and then remove engi ne room harness connector from frame assembly.
Vehicle rear side
Remove EVAP hose (canister side).
Remove rear final drive breather hose from air breather tube (body side). Refer to DLN-201, "
Removal
and Installation".
Disconnect body harness connector from chassis harness connectors (frame assembly LH rear side).
Refer to PG-150, "
Body Harness"
6. Set safety stand to frame assembly. Release arm of 2-pole lift.
7. Remove cab mounting insulator bolts.
8. Set arm of 2-pole lift to body side sill portion of body.
9. Slowly lift 2-pole lift.
CAUTION:
Check that there is no inte rference with the vehicle.
Check that all connection points are disconnected.
10. Remove cab mounting insulator.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
Before starting engine, check oil/fl uid levels including engine coolant and engine oil. If levels are
less than the required quantity, fill to the specified level. Refer to MA-10, "
Fluids and Lubricants".
Warm up engine thoroughly to check that there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Revision: 2010 May2011 QX56
DLN-3
CEF
G H
I
J
K L
M A
B
DLN
N
O P
U1000 CAN COMM CIRCUIT ......................... ....91
Description .......................................................... ....91
DTC Logic ...............................................................91
Diagnosis Procedure ...............................................91
U1010 CONTROL UNIT (CAN) ..........................92
Description .......................................................... ....92
DTC Logic ...............................................................92
Diagnosis Procedure ...............................................92
POWER SUPPLY AND GROUND CIRCUIT ......93
Description .......................................................... ....93
Diagnosis Procedure ...............................................93
4WD WARNING LAMP ......................................97
Component Function Check ................................ ....97
Diagnosis Procedure ...............................................97
4WD INDICATOR LAMP ....................................98
Component Function Check ................................ ....98
Diagnosis Procedure ...............................................98
SYMPTOM DIAGNOSIS ..............................99
HEAVY TIGHT-CORNER BRAKING SYMP-
TOM OCCURS . .............................................. ....
99
Description .......................................................... ....99
Diagnosis Procedure ...............................................99
4WD MODE DOES NOT CHANGE ..................100
Description .......................................................... ..100
Diagnosis Procedure .............................................100
4WD MODE INDICATOR LAMP CONTINUES
BLINKING .........................................................
101
Description .......................................................... ..101
Diagnosis Procedure .............................................101
4WD WARNING LAMP BLINKS QUICKLY .....102
Description .......................................................... ..102
4WD WARNING LAMP BLINKS SLOWLY .....103
Description .......................................................... ..103
Diagnosis Procedure .............................................103
INFORMATION DISPLAY IS NOT DIS-
PLAYED ...........................................................
104
Description .......................................................... ..104
Diagnosis Procedure .............................................104
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ..........................
105
NVH Troubleshooting Chart ................................ ..105
PERIODIC MAINTENANCE .......................106
TRANSFER FLUID ......................................... ..106
Inspection ............................................................ ..106
Draining .................................................................106
Refilling .................................................................106
REMOVAL AND INSTALLATION .............107
TRANSFER CONTROL UNIT .........................107
Removal and Installation ..................................... ..107
4WD MODE SWITCH ......................................108
Removal and Installation .......................................108
FRONT OIL SEAL ...........................................109
Exploded View .......................................................109
Removal and Installation .......................................109
REAR OIL SEAL .............................................111
Exploded View .......................................................111
Removal and Installation .......................................111
Adjustment .............................................................112
TRANSFER CONTROL ACTUATOR .............114
Exploded View .......................................................114
Removal and Installation .......................................114
Inspection ..............................................................114
TRANSFER HI-LO POSITION SENSOR ........116
Exploded View .......................................................116
Removal and Installation .......................................116
Inspection ..............................................................116
TRANSFER ROTARY POSITION SENSOR ...117
Exploded View .......................................................117
Removal and Installation .......................................117
Inspection ..............................................................118
TRANSFER LOCK POSITION SENSOR ........119
Exploded View .......................................................119
Removal and Installation .......................................119
Inspection ..............................................................119
TRANSFER FLUID TEMPERATURE SEN-
SOR .................................................................
120
Exploded View .......................................................120
Removal and Installation .......................................120
Inspection ..............................................................120
UNIT REMOVAL AND INSTALLATION ....121
TRANSFER ASSEMBLY ................................121
Exploded View ..................................................... ..121
Removal and Installation .......................................121
INPUT OIL SEAL ............................................123
Exploded View .......................................................123
Removal and Installation .......................................123
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... ...........................................
124
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
124
General Specifications ......................................... ..124
FRONT PROPELLER SHAFT: 2F P15
PREPARATION ........ .................................
125
PREPARATION ...............................................125
Revision: 2010 May2011 QX56