QX56 Service Procedure
QX56 Service ProcedureWARNING:
Never open the cooling system when the engine is hot. Serious burns may occur from hot high pressure engine coolant escaping from the cooling system.
NOTE:
During this procedure you will remove several similar size bolts with different lengths. It is important to keep track of which length bolt goes in which location.
1. Write down the radio station presets.
2. Write down the customer settings for the Automatic Temperature Control / Climate Control system. (Refer to the Service Manual as needed.)
3. Release fuel system pressure as follows:
a. Turn the ignition ON.
b. Connect CONSULT-III or CONSULT-III plus.
c. Perform FUEL PRESSURE RELEASE in ENGINE WORK SUPPORT.
d. Start engine.
e. After engine stalls, crank it two or three times to release all fuel pressure.
f. Turn ignition OFF, disconnect CONSULT.
4. Disconnect both battery cables; negative cable first.
5. Remove the engine cover (see Figure 1).
a. Remove 2 bolts at the front of the cover.
b. Lift the front of the cover to access and loosen the rear bolts.
6. Disconnect the 2 breather hoses at the points shown in Figure 2.
7. Disconnect EVAP solenoid electrical connector (see Figure 3).
8. Disconnect EVAP solenoid harness mount from the intake manifold.
9. Remove the air intake tube as follows:
a. Loosen band clamps at each end of the air intake tube.
b. Unclip and loosen the top of the air cleaner housing.
c. Take the air intake tube loose and place it out of the way.
NOTE:
The EVAP hose can remain attached to the air intake tube.
d. Cover air breather openings with clean rags to prevent debris entry.
10. Remove the throttle body:
^ Leave coolant hoses connected to the throttle body.
WARNING:
Do not loosen or remove spring clamps on coolant hoses. Hot coolant may come out if the engine is hot.
a. Disconnect electrical connector from the throttle body.
b. Remove the 4 mounting bolts.
c. Pull the throttle body away from the intake manifold and place it to the side, away from the manifold.
d. Cover the intake manifold openings with clean rags to prevent debris entry.
11. By hand, remove the fuel pump foam insulator.
12. Remove the harness bracket mounting bolt (passenger side of engine) shown in Figure 6.
13. Disconnect the positive crankcase ventilation (PCV) hoses from the intake manifold; both sides.
a. Loosen spring clamps.
b. Disconnect hoses and position them out of the way.
14. Disconnect the manifold absolute pressure sensor electrical connector (see Figure 8).
NOTE:
The manifold absolute pressure sensor is mounted on the rear of the intake manifold. It can be accessed and disconnected from the passenger side of the intake manifold.
15. Remove 10 bolts securing the intake manifold to the engine (see Figure 9).
16. Remove the intake manifold from the engine and place clean rags over the intake ports to prevent debris from entering the engine.
17. Remove insulators covering the fuel rails.
18. Disconnect the fuel rail pressure sensor electrical connector.
19. Carefully inspect the area around the fuel rail pressure sensor for any evidence of leakage.
No evidence of leakage - go to the next step.
Evidence of leakage is found:
a. Remove the fuel rail pressure sensor.
b. Replace the Gasket (sealing washer).
c. Reinstall the fuel rail pressure sensor.
d. Go to the next step.
20. Torque the fuel rail pressure sensor as follows:
a. Measure the length of your torque wrench between the center of the handle and the center of the square drive as shown in Figure 12.
b. Set your torque wrench using the table above.
c. Attach special tool J-50991 to your torque wrench - use an extension if needed.
d. Torque the sensor to the specified torque.
NOTE:
Make sure to keep the extension tool (J-50991) straight (in line) with the torque wrench as shown in Figure 14.
21. Re-connect the fuel rail pressure sensor electrical connector.
IMPORTANT:
You cannot connect the sensor after the intake manifold is installed.
Tighten Additional Fuel Rail Connections Before Reassembly
22. Torque the bolts shown in Figure 15:
11 N-m (1.1 Kg-m, 97 in-lb)
23. Torque the flange nuts shown in Figure 16:
33.4 N-m (3.4 Kg-m, 25 ft-lb)
^ Use a short 19 mm crowfoot wrench.
24. Reinstall insulators covering the fuel rails.
Reassembly
25. Install new intake manifold gaskets.
NOTE:
^ For vehicles in dealer inventory (less than 125 miles), new gaskets are not needed.
^ Clean and inspect the old gaskets. Make sure gaskets are not torn or cut and they are installed properly.
26. Reinstall all parts removed in reverse order.
Reassembly Information
^ Start intake manifold bolts by hand and then tighten in the order shown in Figure 19:
Torque to 10.8 N-m (1.1 Kg-m, 96 in-lb).
^ Install new throttle body gaskets.
NOTE:
For vehicles in dealer inventory (less than 125 miles), new throttle body gaskets are not needed. Clean and inspect the old gaskets. Make sure gaskets are not torn or cut and they are installed properly.
^ Start throttle body bolts by hand and then torque to 10 N-m (1.0 Kg-m, 89 in-lb).
^ Before installing the engine cover, check the following items:
Manifold absolute pressure sensor harness is connected
Breather hoses installed and spring clamps secured
Breather Hose aligned with mounting locations (tabs) on intake manifold
Air intake tube clamps tight
EVAP hose installed and spring clamp secured
EVAP solenoid harness connector secured
Fuel pump foam insulator installed
Positive crankcase ventilation hoses attached and clamps secured
Harness bracket (passenger side of intake manifold) secured
27. Reconnect battery cables, positive cable first.
28. Keep foot off of the brake and cycle ignition OFF > ON, wait 3 seconds, > OFF. Repeat 3 times to build pressure in the fuel system.
29. Start the engine and make sure no warning lights are ON, and confirm the engine will rev past 4000 rpm.
30. Reinitialize each auto-up power window as follows:
a. Turn ignition ON.
b. Open window all the way DOWN.
c. Pull all the way UP on the switch and HOLD (close the window completely), continue to HOLD for 4 seconds after window is completely closed.
d. Confirm auto up/down operates correctly.
31. Reinitialize the automatic back door as follows:
a. Make sure the back door is fully closed.
b. Perform automatic back door open/close operation.
c. Check for noise or malfunctioning during operation.
d. Check that hazard lamps blink and that warning buzzer operates.
NOTE:
Never touch back door or allow foreign materials to be pinched in door when performing automatic back door open/close operation.
32. Reset the customers settings for the Automatic Temperature Control / Climate Control system. (Refer to the Service Manual as needed.)
33. Reset the clock and radio station presets.
34. Inform the customer they will need to reset their ADP (Automatic Drive Positioner).