Foreword

This manual provides general servicing information of Xiali N5 vehicle.

Applicable vehicle model: Xiali N5 series.
Any servicing information unmentioned in this manual can be found in the following manuals:

Name of manuals
Xiali Vehicle Servicing Manual
Xiali N5 Sedan Circuit Diagram
Servicing Manual of CA4GA1 Engine Telematics Control System
CA3GA2 Series Engine Servicing Manual
CA4GA1 Series Engine Servicing Manual
 Notes
This manual does not cover all necessary information related to repairing and services. This manual is applicable to those
are technically professional or qualified. If those are neither technically professional nor qualified carry out the repairing
work only using this manual or do not use any special equipment and tool, anyone around him/her (including himself/herself)
might encounter serious injury, even damaging vehicle of the customer.
All steps below must be observed in order to avoid dangerous operation and prevent vehicles of customer from being
damaged.
● It is required to completely read this manual. It is extremely important to understand all contents in “Instructions and
Notes for Servicing" in chapter Introduction.
● Methods provided in this manual are efficacious for repairing and servicing. It is always required to use recommended
special tools in carrying out works in procedures specified in this manual. If tool or servicing method which is not
special or not recommended will be used, it is required to ensure that no technical risk exists, and nobody will
encounter injury and no vehicle will be damaged before operation.
● Original parts shall be used in replacing old parts. Do not use any inferior parts. CAUTION: “Caution” and “Note" in
this manual have different meanings. It is required to understand and differentiate them. Correct understanding and
differentiation may reduce risk of injury or decrease possibility of damaging vehicle in providing service and repairing.
It is required to know that these “CAUTIONs” and “NOTEs” are not complete. Redundant reminders might cause hazard.
 Introduction
Identification information (code)
VIN and Engine Model Number

1. VIN
VIN is engraved in engine compartment as shown in figure.
A. VIN
B. Vehicle name plate

2. Engine model and identification number are engraved in the

engine cylinder block as shown in figure.

Engine model and

identification
number

Flywheel

CA3A+ Engine

Engine model
and
identification
number

Flywheel

CA4GA1 Engine
 Notes for Repairing
Notes for Repairing ··································································· 1-1
Technical Parameters for Repairing ················································ 1-6
 Notes for Repairing

Notes for Repairing

1. It is required to use protection plate, seat cushion and floor mate to prevent vehicles from being damaged or
contaminated.
2. Disassembly of parts
a. Place the removed parts in a reasonable sequence. Divide parts into two groups – one requiring replacement and
another which is reusable – in order to facilitate reassembly.
b. When dismantling complicated parts, it is better to make marks or mating signs in proper non-working surface of it
in order to facilitate mounting it back to original place correctly in reassembly.
c. Each time when a part is removed, it is required to check the installation condition of it and confirm that it has been
deformed, damaged, worn or scraped.
d. Reusable parts (excluding grease sealed bearing) shall be completely rinsed.
e. For reusable parts, it is required to carry out careful check or measurement.
3. Assembly of parts
a. Comply with all regulations related to bolt tightening torque. Only torque spanner must be used. Fit acceptable parts
as per specified standards (such as, specified adjusted value and tightening torque).
b. It is required to unscrew or screw bolts gradually in several stages. Extra care shall be taken of observation to
prevent the tightened parts from being deformed or damaged.
c. Positions for installation of bearings shall be blown on by compressed air, not cleaned by clothes. Pay attention to
protect mating surface of bearings. Those who carry out cleaning work shall wear goggles to protect eyes.
d. Similar parts like packings, gaskets and oil seals must be replaced with new ones.
e. Parts which can not be used repeatedly, such as cotter pin, gaskets and oil seals must be replaced with new ones.
Parts which can not be used repeatedly shall be marked by “★”in parts diagrams.
4. It is required to use special repair tools as required in order to increase efficiency and maintain a certain precision.
5. Do not smoke in repairing. Do not let any fire source close to working station.
6. Engine warming up state indicates coolant temperature of at least up to 75～85℃, and engine oil temperature of at
least up to 65℃.
The temperature can be confirmed by observing status after the cooling fan motor just stops.
7. Vehicles equipped with catalytic converters.
Note: If lots of unburned gasoline enters the catalytic converter, it will cause overheating or even fire. In order to
prevent accidents, it is required to observe the follows and explain related notes for users.
(a) Only unleaded gasoline can be used.
(b) Avoid running the engine at idling for a long time. Do not let engine run at idling above 20 minutes.
(c) Do not conduct spark over test.
(1) It is permitted to conduct the spark over test for spark plug only when it is necessary. However, it is required to keep
the spark over test last as short as possible.
(2) Do not run the engine for a long time in test. At the same time, it is required to cut off fuel supply (ensure that
injector nozzle will not inject oil to the cylinder).
(d) Avoid lasting the engine compression test for a long time.
It is required to keep the engine compression test as short as possible (ensure that injector nozzle will not inject oil to
the cylinder).
(e) Do not run the engine when fuel in fuel tank is almost used up.
Otherwise, it will cause disruption in combustion and then overload the catalytic converter.
(f) Do not coast with ignition system closed.
(g) Do not put the used catalytic converter together with oiled or lubricated parts.

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 Notes for Repairing

8. Requirements for battery cables in repairing

(a) Cable in negative terminal (-) must be disconnected from the
battery before carrying out electrical repair work.
(b) Power supply shall be switched off and the negative terminal (-)
must be off in checking and repairing.
(c) It is required to loosen the locking nuts in cable and lift up the cable
to avoid damaging battery terminals. Do not twist it or pry on it by
force.
(d) Cleaning cloth shall be used for cleaning of battery terminals
and cable terminals. Do not scrape them using a file or rough
objects.
(e) It is required to loosen nuts in connecting the cable connector
with the battery terminal. Screw nuts again after installation. Do
not connect the cable onto the battery terminals in a knocking
manner by a hammer.
(f) It is always required to cover well the positive terminal (+) cap

9. Precoated parts
Precoated parts means parts which have been coated before delivering
out from the parts manufacturer.
(a) It is required to apply specified coat again to the precoated parts
after they are screwed again, loosened or moved in any manner.
Sealant
(b) It is required to clean off the former sealant onto the parts and
dry them using compressed air before using the precoated parts
again. And then apply specified coat on the parts.

(c) Precoated parts are marked by “◆”in parts diagrams.

10. It is required to use new fuse with specified rated current in

Rated current same as the rated current of
medium and high current fuses replacement. Do not use fuses with rated current above or below
the specified value.

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 Notes for Repairing

Illustration Sign Parts name Abbreviation

Fuse FUSE

Current fuse M-FUSE

High current fuse H-FUSE

Fuse line FL

Circuit breaker CB

11. Extra care shall be taken in propping up and supporting the

vehicle using a jack. Do it only after finding a proper point of
support.
● Release hand brake and keep the transmission at neutral gear.
● It is required to put a cushion under the wheel of another side to
keep safe if a vehicle is supported up using a jack in the front or
rear.
● After the vehicle is lift up, it is required to support it with a
bracket. If only a jack supports the vehicle while carrying out
operations though a small task which will be finished quickly, it
is very dangerous.
12. Comply with the following instructions to avoid damaging
Wrong Right
parts:
① Do not open the ECU (electronic control unit) cover or housing,
unless absolutely necessary (Touching the integrated circuit (IC)
pins may damage the IC due to the static).）
② It is required to hold the hose end rather than the intermediate
part while pulling out the vacuum hose.
③ After pulling off the circuit connectors, it is required to pull the
connector and not to involve cable.
④ Do not let electrical elements (such as sensor or relays) fall
Wrong Right
down. If they are already fallen down to the hard ground, it is
required to replace it immediately.
⑤ Protect electrical elements when cleaning the engine using
steam. Store the control units, independent ignite and air filter in
a safe place against water ingress.
⑥ Do not remove or install the temperature control switch or the
temperature sensors using an air impact wrench.
⑦ Extra care shall be taken in inserting the tester probe to avoid
1-3
 Notes for Repairing
bending the connection terminals in check that the conductor
connector is conductive.
⑧ Do not mount the hose by force onto the connection pipe with
excessive size when in using a vacuum gauge. It is
recommended to use stepped connectors for connection. Hoses
being extended might cause leakage.

13. Vacuum hoses shall be labeled before removing;

(1) It is required to label the vacuum hose before removing it to
facilitate recognition in re-connection.
(2) Check that vacuum hoses are connected well after installation.
14. Unless otherwise specified, all thermistor mount shall be
measured at room temperature 20℃ （68F）. Resistance measured
at high temperature might exceed specified value, especially
soon after the vehicle stops. Measurement shall be carried out
after the engine is cooled down.

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 Notes for Repairing
Vehicle lifting
1. Lifting points and safe support points of vehicle

Lifting points
Front end……Engine mounting lower cross member (put a jack under this member. Pay attention to the exhaust pipes)
Rear end……Center of rear floor cross member

Engine mounting lower cross member Rear floor cross member

Jack support points

Safe bracket support points

Safe bracket support points

Left and right sides of vehicle are provided four supporting points. (The supporting points shall be welded
for strengthening. Do not support the complete vehicle onto points except for specified points)

Retightened part

2. Support points of twin post auto lift

Align the support cushion of twin post auto lift with the safe
support points as shown in left figure.

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 Notes for Repairing
Technical parameters for repairing

— Models and characteristics

Transmission Model and

Vehicle Model Body Type Engine Model
Type
Manual transmission
TJ7103UE4 Three-box CA3GA2+
5T063A
Manual transmission
TJ7103UE3 Three-box CA3GA2+
5T063A
Manual transmission
TJ7133UE4 Three-box CA4GA1
5T065-2D2
Manual transmission
TJ7133UE3 Three-box CA4GA1
5T065-2D2

— Parameters of complete vehicle

Vehicle Model TJ7103UE4 TJ7103UE3 TJ7133UE4 TJ7133UE3

Length mm 4155 4155
Width mm 1645 1645
Height mm 1435 1435
Wheel Base mm 2405 2405
Front Tread mm 1405 1405
Rear Tread mm 1385 1385
Minimum Ground Clearance (Full
125 125
Load) mm
Curb Weight kg 905 915
Max. Gross Weight 1280 1290
Number of passengers Person 5 5

1-6
 Notes for Repairing

— Engine parameters

Model CA3GA2+ CA4GA1

In-line 3-cylinder, four-stroke
Type In-line 4-cylinder, four-stroke gasoline engine
gasoline engine
Bore and Stroke mm 76×73 73×80
Displacement ml 993 1339
Rated Power kW/r/min 50.5 / 6000 67 / 6000
Maximum Torque Nm/r/min 90 / 3600 120 / 4400

Valve Clearance (Cold Intake Valve 0.20±0.05 0.20±0.03

State) mm Exhaust Valve 0.25±0.05 0.30±0.03
Spark Plug Type K7RTC K20R-U11 FR8LCX
Spark Plug Clearance mm 0.7～0.8 1.0～1.1

450±50 (New Poly V-Belt)

Tension of Poly V-Belt N 650±50
400±50 (Old Poly V-Belt)

Remarks: New poly V-belt means a belt which has not been used for above 5 minutes in running engine.
New poly V-belt means a belt which has been used for above 5 minutes in running engine.

Engine lubricant:
CA3GA2+ CA4GA1
Total Volume 3.2 4.0
API SJ or above API SL
Quality and Viscosity Level
5W/30 or 10W/30 5W/40
Recommended engine oil viscosity chart (SAE)

Cooling system
Total volume: 5.5L
Coolant type: Glycol base coolant
The glycol base coolant can well protect the aluminum parts of engine.
Do not use glycol coolant or common water.
Fuel
Fuel type: unleaded gasoline of research octane number 93# or above
E3 vehicle must use special fuel for nation III standard (OBD).

1-7
 Notes for Repairing
E4 vehicle must use special fuel for nation IV standard.
Rated volume of fuel tank: 37L
It is required to use the correct fuel gun in filling. Fuel gun shall be completed inserted into the fuel tank. Do not lean it
against the filler edge. Once the gun is automatically switched off, it indicates that the fuel tank is full. Do not continue
filling. Otherwise the fuel tank has no space for fuel and fuel will overflow so that it might cause fire or explosion if
temperature arises.

— battery
Charging current:
Quick charging maximum 15A
Slow charging maximum 5A

— Clutch
Pedal free travel: (mm)
5T065 transmission: 5～15
5T063A transmission: 15～30

— Manual transmission
Transmission oil volume: (L)
5T065 transmission: 1.8～2.0L
5T063A transmission: 1.9～2.05L
Transmission oil specification:
API GL-4，SAE：80W／90
Please select superior lubricant in extremely cold regions.

Note
Use of unspecified transmission oil will damage
the transmission.

— Brake
When the engine is running and force of 500N is applied to the brake pedal, the reserved travel between the pedal and
the floor shall not be below 65mm.
Brake pedal free travel: 1～5 mm
If force of 200N is applied to pull the parking brake lever, clatter sounds for 4-9 times.
Brake fluid: HZY4 in GB12981-2003
(Manufacturer: Original Shenyang Chemical Co., Ltd.

— Steering
Steering wheel free travel: 1～10 mm

— Tires
Tire model:
175／65R14 or
165／70R13
Tire pressure:
175／65R14:

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 Notes for Repairing
Front tires: 230 kPa Rear tires: 210 kPa

165／70R13:
Front/rear tires 200kPa

Tightening torque of tire nuts: 103 N·m

— Fuse
Inside engine compartment
TJ7103 series 氧传感器 Oxygen sensor 2 号继电器 #2 relay
油泵 Oil pump 冷凝器风扇继电器 Condenser fan relay
备用 Standby 起动机继电器 Starter relay
空调 A/C 空调继电器 Air conditioning relay
左前照灯 Left headlamp 散热器风扇 30A Radiator fan 30A
右前照灯 Right headlamp 起动机 30A Starter 30A
散热器风扇继电器 Radiator fan relay 电动窗 30A Power window 30A
主继电器 Primary relay 冷凝器风扇 30A Condenser fan 30A
油泵继电器 Oil pump relay

TJ133 series

备用 Standby 2 号继电器 #2 relay

空调 A/C 冷凝器风扇继电器 Condenser fan relay
左前照灯 Left headlamp 起动机继电器 Starter relay
右前照灯 Right headlamp 空调继电器 Air conditioning relay
散热器风扇继电器 Radiator fan relay 散热器风扇 30A Radiator fan 30A
主继电器 Primary relay 起动机 30A Starter 30A
油泵继电器 Oil pump relay 电动窗 30A Power window 30A
冷凝器风扇 30A Condenser fan 30A

1-9
 Notes for Repairing
Below instrument panel
TJ7103 series
闪光继电器 Flasher relay 暖风 Warm air
电动窗继电器 Power window relay 电动助力转向 Electric assisted steering
喇叭继电器 Horn relay 备用 Standby
后除霜继电器 Rear window defroster relay 备用 Standby
刮水器 Wiper 喇叭 Horn
仪表 Instrument 制动灯 Stop lamp
报警灯 Warning lamp 示宽灯 Width-indicator
后除霜 Rear window defroster 收音机 Radio
点烟器 Cigarette-lighter 门锁 Door lock

Note: 1. Vehicles equipped with electric

power-assisted steering have fuse of
electric power-assisted steering.

TJ7133
闪光继电器 Flasher relay 暖风 Warm air
节气门继电 Throttle relay 节气门 Throttle
器
电动窗继电 Power window relay 电动助力转 Electric assisted
器 向 steering
喇叭继电器 Horn relay 备用 Standby
后除霜继电 Rear window defroster 备用 Standby
器 relay
安全气囊 Air bag 喇叭 Horn
刮水器 Wiper 制动灯 Stop lamp
仪表 Instrument 示宽灯 Width-indicator
报警灯 Warning lamp 收音机 Radio
series 后除霜 Rear window defroster 门锁 Door lock
Note: 1. Vehicles equipped with ABS have 点烟器 Cigarette-lighter
fuse of ABS
2. Vehicles equipped with airbag
have fuse of airbag.
3. Vehicles equipped with electric
power-assisted steering have fuse
of electric power-assisted
steering.
Note
Fuse labels shown in the manual
may be different from fuse labels
in customer vehicle due to design
variation. In this case, fuse labels
in vehicle shall prevail.
1-10
 Notes for Repairing

— Parameters of wheels alignment

Kingpin inclination 2° 55′±45′

Parameters for front wheel Wheel camber 0°20′±45′

alignment Kingpin toe-in and wheel camber 12° ±45′

Toe-in（mm） 1±1

Wheel camber -0° 40′±45′

Parameters for rear wheel
alignment Toe-in （mm） 5 13

Vehicle height A－B（mm） 69.5±15

Body status in measurement
Vehicle height C－D（mm） 25±15

Center of front wheel Center of rear wheel

Center of rear suspension

Center of front lower arm #1 swing arm and body
and body mounting bolt mounting bolt

Note: When adjusting vehicle body under no-load, first meet A－B and C－D, and then measure parameters for wheels
alignment. Measured wheel alignment parameters shall meet values listed in wheels alignment parameter table.

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