FRONT WHEEL HUB AND KNUCKLEFAX-19
< REMOVAL AND INSTALLATION > [4WD]
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7. Set suitable jack under lower link.
8. Remove shock absorber mounting bolt from lower link. Refer to FSU-10, "
Removal and Installation".
9. Separate upper link from steering knuckle, using the ball joint remover (commercial service tool), and
remove upper link.
CAUTION:
Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover
from suddenly coming off.
Never damage ball joint boot.
10. Remove cotter pin, and then loosen wheel hub lock nut.
11. Put matching mark on drive shaft and wheel hub and bearing assembly. CAUTION:
Use paint or similar substance for matc hing marks. Never scratch the surface.
12. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing assembly from drive shaft.
CAUTION:
Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint.
Never allow drive shaft to hang down without support for or joint sub-assembly, shaft and the
other parts.
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive shaft cannot be separated even after
performing the above procedure.
13. Remove wheel hub lock nut.
14. Remove wheel hub and bearing assembly, and then remove splash guard.
15. Remove lower link from steering knuckle. CAUTION:
Never damage ball joint boot.
16. Remove steering knuckle.
17. Remove hub bolts (1) from wheel hub and bearing assembly, using the ball joint remover (A) (commercial service tool).
CAUTION:
Remove hub bolt only when necessary.
Never hammer the hub bolt to avoid impact to the wheel
hub and bearing assembly.
Pull out the hub bolt in a di rection perpendicular to the
wheel hub and bearing assembly.
18. Perform inspection after removal. Refer to FAX-20, "
Inspection".
INSTALLATION
Note the following, and install in the reverse order of removal.
Place a suitable washer (A) as shown in the figure to install the hub
bolts (1) by using the tightening force of the nut (B).
CAUTION:
Check that there is no cl earance between wheel hub and
bearing assembly, and hub bolt.
Never reuse hub bolt.
Use the following torque range for tightening the wheel hub lock nut.
CAUTION:
Since the drive shaft is assembled by press-fitting , use the tightening torque range for the wheel
hub lock nut.
Be sure to use torque wrench to tighten th e wheel hub lock nut. Never use a power tool.
Perform the final tightening of each of parts under unladen conditions, which were removed when removing
wheel hub and bearing assembly and steering knuckle.
JPDIF0299ZZ
: 118 – 123 N·m (12.1 – 12.5 kg-m, 87 – 90 ft-lb)
JPDIF0300ZZ
Revision: 2010 May2011 QX56
FAX-20
< REMOVAL AND INSTALLATION >[4WD]
FRONT WHEEL HUB AND KNUCKLE
Never reuse cotter pin.
Perform inspection after installation. Refer to
FAX-20, "
Inspection".
InspectionINFOID:0000000006225398
INSPECTION AFTER REMOVAL
Check components for deformation, cracks, and other damage. Replace it if necessary.
Ball Joint Inspection
Check boots of lower link and steering outer socket ball joint for breakage, axial play, and torque. Refer to
FSU-15, "
Inspection" and ST-46, "Inspection".
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-134, "FRONT WHEEL SENSOR :
Exploded View".
2. Check the wheel alignment. Refer to FSU-7, "
Inspection".
3. Adjust neutral position of steering angle sensor. Refer to BRC-64, "
Work Procedure".
Revision: 2010 May2011 QX56
FRONT DRIVE SHAFTFAX-23
< REMOVAL AND INSTALLATION > [4WD]
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Never damage ball joint boot.
11. Remove cotter pin, and then loosen wheel hub lock nut.
12. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing assembly from drive shaft.
CAUTION:
Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint.
Never allow drive shaft to hang down without support for or joint sub-assembly, shaft and the
other parts.
NOTE:
Use suitable puller, if wheel hub and bearing assembly and drive shaft cannot be separated even after
performing the above procedure.
13. Remove wheel hub lock nut.
14. Remove fender protector. Refer to EXT-23, "
FENDER PROTECTOR : Removal and Installation".
15. Remove drive shaft from front final drive using the drive shaft attachment [SST: KV40107500 ( −)] (A) and a sliding ham-
mer (commercial service tool) (B) while inserting tip of the drive
shaft attachment between housing and front final drive.
CAUTION:
Never place drive shaft joint at an extreme angle when
removing drive shaft. Also be careful not to overextend
slide joint.
Confirm that the circular clip is attached to the drive shaft.
16. Perform inspection after removal. Refer to FAX-28, "
Inspection".
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Always replace final drive side oil seal with new one when installing drive shaft. Refer to DLN-160,
"Removal and Installation"
Place the protector [SST: KV38106300 (−)] (A) onto final drive
to prevent damage to the oil seal while inserting drive shaft. Slide
drive shaft sliding joint and tap with a hammer to install securely.
CAUTION:
Check that circular clip is completely engaged.
Use the following torque range for tightening the wheel hub lock nut.
CAUTION:
Since the drive shaft is assembled by press-fitting, use the tightening torque range for the wheel hub lock nut.
Be sure to use torque wrench to tighten th e wheel hub lock nut. Never use a power tool.
Perform the final tightening of each of parts under unladen conditions, which were removed when removing
wheel hub and bearing assembly and steering knuckle.
Never reuse cotter pin.
Perform inspection after installation. Refer to FAX-28, "
Inspection".
WHEEL SIDE
WHEEL SIDE : Disassembly and AssemblyINFOID:0000000006225404
DISASSEMBLY
1. Fix shaft with a vise.
CAUTION:
Protect shaft when fixing with a vi se using aluminum or copper plates.
2. Remove dust shield from joint sub-assembly.
3. Remove boot bands and then remove boot from joint sub-assembly.
JPDIF0004ZZ
: 118 – 123 N·m (12.1 – 12.5 kg-m, 87 – 90 ft-lb)
JPDIF0023ZZ
Revision: 2010 May2011 QX56
FSU-12
< REMOVAL AND INSTALLATION >
FRONT COIL SPRING AND SHOCK ABSORBER
When installing the shock absorber attachment to shock absorber, wrap a shop cloth around
shock absorber to protect it from damage.
2. Compress coil spring using a spring compressor (commercial service tool), and install it onto shock absorber.
CAUTION:
Be sure a spring compressor is securely attach ed to coil spring. Compress coil spring.
Set coil spring so that its paint marks face downward.
3. Apply soapy water to dust cover. CAUTION:
Never use machine oil.
4. Install dust cover, bound bumper cover, rubber seat , bushings, tube, shock absorber mounting bracket,
and washer to shock absorber.
Install the shock absorber mounting bracket (1) as shown in the figure.
Check that the lower end of the coil spring (B) is positioned at the spring lower seat of the shock absorber.
5. Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut to the specified torque.
6. Gradually release a spring compressor, and remove coil spring. CAUTION:
Loosen while making sure co il spring attachment position
does not move.
7. Remove the shock absorber attachment from shock absorber.
Inspection and AdjustmentINFOID:0000000006225644
INSPECTION AFTER REMOVAL (WITH HBMC)
Shock Absorber assembly
Check shock absorber assembly for oil leakage or other malfunctions. Replace it if necessary.
INSPECTION AFTER DISASSEMBLY (WITHOUT HBMC)
Shock Absorber
Check the following items, and replace the part if necessary.
Shock absorber for deformation, cracks or damage.
Piston rod for damage, uneven wear or distortion.
Oil leakage.
Shock Absorber Mounting Bracket and Rubber Parts Inspection
Check shock absorber mounting bracket for cracks and rubber parts for wear. Replace it if necessary.
Coil Spring
Check coil spring for cracks, wear or damage. Replace it if necessary.
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-134, "FRONT WHEEL SENSOR :
Exploded View".
2. Check wheel alignment. Refer to FSU-7, "
Inspection".
Angle (a) : 90
°
A : Shock absorber mounting bracket bolt
JPEIA0221ZZ
Revision: 2010 May2011 QX56
FSU-18
< REMOVAL AND INSTALLATION >
UPPER LINK
INSTALLATION
Note the following, and install in the reverse order of removal.
Perform final tightening of bolts and nuts at the vehicle installation position (rubber bushing), under unladenconditions with tires on level ground.
Perform inspection after installation. Refer to FSU-18, "
Inspection".
InspectionINFOID:0000000006225651
INSPECTION AFTER REMOVAL
Appearance
Check the following items, and replace the part if necessary.
Upper link and bushing for deformation, cracks or damage.
Ball joint boot for cracks or other damage, and also for grease leakage.
Ball Joint Inspection
Manually move ball stud to confirm it moves smoothly with no binding.
Swing Torque Inspection
1. Move the ball joint at least ten times by hand to check for smooth movement.
2. Hook a spring balance (A) at cotter pin mounting hole. Confirm
spring balance measurement value is within specifications when
ball stud begins moving.
If swing torque exceeds standard range, replace upper link assem- bly.
Rotating Torque Inspection
1. Move the ball joint at least ten times by hand to check for smooth movement.
2. Attach mounting nut to ball stud. Check that rotating torque is
within specifications with a preload gauge [SST: 3127S000 (J-
25765-A)] (A).
If rotating torque exceeds standard range, replace lower link assembly.
Axial End Play Inspection
1. Move the ball joint at least ten times by hand to check for smooth movement.
2. Move tip of ball stud in axial direction to check for looseness.
If axial end play exceeds standard range, replace upper link assembly.
INSPECTION AFTER INSTALLATION
1. Check wheel sensor harness for proper connection. Refer to BRC-134, "FRONT WHEEL SENSOR :
Exploded View".
2. Check wheel alignment. Refer to FSU-7, "
Inspection".
3. Adjust neutral position of steering angle sensor. Refer to BRC-64, "
Work Procedure".
Swing torque : Refer to
FSU-21, "
Ball Joint".
JPEIA0005ZZ
Rotating toque : Refer to FSU-21, "Ball Joint".
PDIA1258E
Axial end play : Refer to FSU-21, "Ball Joint".
Revision: 2010 May2011 QX56
SERVICE DATA AND SPECIFICATIONS (SDS)
FSU-21
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Wheel AlignmentINFOID:0000000006225652
*1: The minimum value and maximum value is the same as the nominal value.
Measure value under unladen
*2 conditions.
*2: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.
Ball JointINFOID:0000000006225653
Wheel HeightINFOID:0000000006225654
Item Standard
Measurement wheel Left side Right side
Camber
Degree minute (Decimal degree) Minimum
−0 °45 ′ ( −0.75 °) −0°55 ′ ( −0.91 °)
Nominal 0 ° 00 ′ (0.00 °) −0°10 ′ ( −0.17 °)
Maximum 0 ° 45 ′ (0.75 °)0 ° 35 ′ (0.58 °)
Left and right difference 0 ° 33 ′ (0.55 °) or less
Caster
Degree minute (Decimal degree) Minimum 2
° 20 ′ (2.34 °)2 ° 40 ′ (2.67 °)
Nominal 3 ° 05 ′ (3.08 °)3 ° 25 ′ (3.42 °)
Maximum 3 ° 50 ′ (3.83 °)4 ° 10 ′ (4.16
° )
Left and right difference 0 ° 45 ′ (0.75 °) or less
Kingpin inclination
Degree minute (Decimal degree) Minimum — —
Nominal
13° 20 ′ (13.33 °)
*113 ° 25 ′ (13.42 °)*1
Maximum — —
To e - i n To t a l t o e - i n
Distance
Minimum In 1.4 mm (0.055 in)
Nominal In 2.4 mm (0.094 in)
Maximum In 3.4 mm (0.134 in)
Toe angle (left wheel or right
wheel)
Degree minute (Decimal degree) Minimum In 0
° 03 ′ (0.05 °)
Nominal In 0 ° 05 ′ (0.08 °)
Maximum In 0 ° 07 ′ (0.11 °)
Item Standard
Swing torque Lower link 0.5 – 6.4 N·m (0.06 – 0.65 kg-m, 5 – 56 in-lb)
Upper link 0.5 – 4.9 N·m (0.06 – 0.49 kg-m, 5 – 43 in-lb)
Measurement on spring balance (groove position) Lower link 11.4 – 145.4 N (1.17 – 14.83 kg, 2.57 – 32.68 lb)
Measurement on spring balance (cotter pin hole position) Upper link 8.1 – 79.0 N (0.83 – 8.05 kg, 1.83 – 17.75 lb)
Rotating torque Lower link 0.5 – 6.4 N·m (0.06 – 0.65 kg-m, 5 – 56 in-lb)
Upper link 0.5 – 4.9 N·m (0.06 – 0.49 kg-m, 5 – 43 in-lb)
Axial end play 0 mm (0 in)
Item Standard
Front (Hf) 903 mm (35.55 in)
Revision: 2010 May2011 QX56
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
PRECAUTIONSIP-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.
ServiceINFOID:0000000006113090
Disconnect battery negative terminal in advance.
Disconnect air bag system line in advance.
Never tamper with or force air bag lid open, as this may adversely affect air bag performance.
Be careful not to scratch pad and other parts.
When removing or disassembling any part, be careful not to damage or deform it. Protect parts, that may get
in the way with a shop cloth.
When removing parts with a screwdriver or other tool, cover the tool surface with vinyl tape to protect parts.
Keep removed parts protected with a shop cloth.
If a clip is deformed or damaged, replace it.
If an unreusable part is removed, replace it with a new one.
Tighten bolts and nuts firmly to the specified torque.
After reassembly is complete, check that each part functions correctly.
Remove stains via the following procedure.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping off the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3%), dip the cloth, then wipe off the stain with the
cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then wipe off the detergent completely. Then
wipe the area with a soft dry cloth.
Never use any organic solvent, such as thinner or benzine.
Revision: 2010 May2011 QX56