SECTION INDEX

FOREWORD 1
Chapter 1 Technical parameter & service specfication 10
Chapter 2 Engine 17
Chapter 3 clutch and clutch operation 40
Chapter 4 Transmission and transmission operation 54
Chapter 5 suspension systems 79
Chapter 6 Front axle and Rear axle 118
Chapter 7 Steering system 144
Chapter 8 Brake systems 211
Chapter 9 wheel assembly 256
Chapter 10 Body 257
Chapter 11 Electrical system 353
Chapter 12 Air conditioning 397
Chapter 13 Assistant safety systems
 FOREWORD
This manual has been prepared to provide information covering general service repairs for the
chassis and body of XIALI.
Applicable Models ： TJ7101 series,TJ7102 series,TJ7111 series,TJ7131 series and TJ7141
series.
For the service specifications and repair procedures other than those listed in this manual,
refer to following manuals.
Manual Name
5A-8A engine repair manual
4GB engine repair manual
3GA2 engine repair manual
Four and five shifted transmission repair manual of XIALI
Electrical wiring diagram of XIALI series
The UAES electrical fuel injection system technical information of XIALI
The Delphi electrical fuel injection system technical manual
The Moto electrical fuel injection system
 CAUTION
This manual does not include all the necessary items about repair and service. This manual is
made for the purpose of the use for the persons who have special techniques and certifications.
In the cases that non-specialized or uncertified technicians perform repair or service only using
this manual or without proper equipment or tool, that may cause severe injury to you or other
people around and also cause damage to your customer's vehicle.
In order to prevent dangerous operation and damages to your customer's vehicle, be sure to
follow the instruction shown below:
●Must read this manual thoroughly. It is especially important to have good understanding all
the contents written in the PRECAUTION of "IN" section.
●The service method written in this manual is very effective to perform repair and service.
When performing the operations following the procedures using this manual, be sure to use
tools specified and recommended. If using non-specified or recommended tools and service
method, be sure to confirm safety of the technicians and any possibility of causing personal
injury or damage to the customer's vehicle before starting the operation.
● If part replacement is necessary, must replace the part with the same part number or
equivalent part. Do not replace it with inferior quality.
● It is important to note that this manual contains various "Cautions" and "Notices" that
must be carefully observed in order to reduce the risk of personal injury during service or
repair, or the possibility that improper service or repair may damage the vehicle or render
it unsafe. It is also important to understand that these "Cautions" and "Notices" are not
exhaustive, because it is important to warn of all the possible hazardous consequences
that might result from failure to follow these instructions.
 Introduction

Identification information (code)

Vehicle identification number and engine number
1．Vehicle identification number
The vehicle identification number is
stamped in the engine cabin, as shown in the
illustration.
A.Vehicle identification number
B. Manufacturer’s plate

2.The engine serial number is stamped on

the engine block, as shown in the illustration .

Repair instructions:
1. Use fender seat and floor covers to keep the vehicle clean and prevent damage.
2. Removal and disassembly.
a. Arrange the disassembled parts in the disassembling order. In addition, separate and arrange
those parts to be replaced and those parts to be reused.
b. When disassembling complicated components, put stamped marks or mating marks on those
sections where such marks do not affect their functions so that the assembling operation may be
performed easily.
c. Each time a part is removed, check the part for the assembled condition, deformation, breakage,
roughness and scratches.
d. Thoroughly clean and wash those parts to be reused. (except the oiliness bearing) .
e. Perform thorough inspection and measurement on those parts to be reused, as required.
3. Installation and assembly.
a. Carefully observe all specifications for bolt tightening torques. Always use a torque
wrench. following the proper procedure and specified standards (adjusting values and tightening,
torque, etc.).
b. When tighten or loose the bolts, It should be divided into several phases. It muse be observed to
avoid deformation or breakage of the parts be tightened.
c. Using compress air blow the part that encased bearing,. Do not using rag in order to protect
the assort surface of bearing, and wearing safety eyeglasses to protect the eyes.
d. Furthermore the parts as fillings, gaskets , oil seals, etc. ensure be replaced by the new one.
e. Non-reusable parts.
Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones.
Non-reusable parts are indicated in the component illustrations by the ‘★’ symbol.
4. For increased work efficiency and improved accuracy, be sure to utilize the special service tools
effectively.
5. No smoking when repairing, and advert to keep any kindling away from the workbench.
6. The warm –vehicle condition of engine means the temperature of cooling water reach 75~80℃,
and the temperature of lube in engine reaches 65℃ at least. Through observing the working
condition when cooling fan electrical moter was just stop to judge these temperature.
7. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and
create a fire hazard. To prevent this, observe the following precautions and explain them to your
customer.
(a) Use only unleaded gasoline,
(b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as
possible.
(2 )While testing never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

8.The requirement of repairing battery line

a) Before performing electrical work,
disconnect the negative (-) terminal cable from
the battery.
b) If it is necessary to disconnect the
battery for inspection or repair, first disconnect
the negative (-) terminal cable.
c) When disconnecting the terminal cable,
to prevent damage to the battery terminal,
loosen the cable nut and raise the cable straight
up without twisting or prying it.
d) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with
a file or other abrasive objects.
e) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut
after installation. Do not use a hammer to tap the cable ends onto the terminals.
f) Be sure the cover for the positive (+) terminal is properly in place.

9. Precoated parts
Precoated parts are coated with a seal lock adhesive at the factory.
(a) If a precoated part is retightened,
loosened or caused to move in any way, it must
be recoated with the specified adhesive.
(b) When reusing precoated parts, clean
off the old adhesive and dry with compressed air.
Then apply the specified seal lock adhesive to the
bolt, nut or threads. Seal Lock Adhesive
（ c ） Precoated parts are indicated in the
component illustrations by the "◆" symbol.

10. When replacing fuses, be sure the new fuse

Medium Current Fuse and High Current
has the correct amperage rating. DO NOT Fuse Equal Amperage Rating
exceed the rating or use one with a lower
rating.
 Part Abbrevia
Illustration Symbol
name tion

FUSE FUSE

MEDIU
M
CURRE M-FUSE
NT
FUSE
HIGH
CURRE
H-FUSE
NT
FUSE

FUSIBL
FL
E LINK

CIRCUI
T
CB
BREAK
ER

11. Care must be taken when jacking up

and supporting the vehicle. Be sure to lift and
support the vehicle at the prop locations.
●Cancel the parking brake on the level
place and shift the transmission Neutral.
●When only the front section or rear section of the vehicle is jacked up, be sure to place
 chocks at the wheels so as to insure safe operations.
●After the vehicle jacked up, be sure to support it on rigid racks. It is extremely dangerous to
do any work on a vehicle raised on a jack alone, even for a small job that can be finished
quickly.
12. Observe the following precautions to avoid damage to the parts:
①Do not open the cover or case of the ECU unless absolutely necessary.
Wrong (If the IC
Correct
terminals are touched, the IC may be destroyed
by static electricity.)
② To disconnect vacuum hoses, pull
off the end, not the middle of the hose.
③To pull apart electrical connectors,
pull on the connector itself, not the wires.
④Be careful not to drop electrical
components, such as sensors or relays. If they
are dropped on a hard floor, they should be
replaced and not reused.
⑤When steam cleaning an engine, Wrong Correct
protect the electronic components, air filter and
emission-related components 、 distributor 、
ignition device from water.
⑥Never use an impact wrench to
remove or install temperature switches or
temperature sensors.
⑦When checking continuity at the
wire connector, insert the tester probe carefully
to prevent terminals from bending.
⑧When using a vacuum gauge, never
force the hose onto a connector that is too
large. Use a step—down adapter for
adjustment, once the hose has been stretched, it
may leak air.
13. Installation and removal of vacuum hose:
（ 1 ） When disconnecting vacuum hoses, use
tags to identify where they should be
reconnected to.
（ 2 ） After completing a job, double check
that the vacuum hoses are properly connected.
14. Unless otherwise stated, all resistance is
measured at an ambient temperature of 20℃
(68oF). Because the resistance may be outside
specifications if measured at high temperatures
immediately after the vehicle has been running, measurement should be made when the engine has
cooled down.
 Vehicle lift
1.JACKING POINTS AND SUPPORTING POINTS OF SAFETY STANDS

Strengthened

fig. 3-1
2.SUPPORTING POINTS OF TWO-POST
LIFT
Align the supporting pads of a two-post lift with
the supporting points of safety stands, as
indicated in the figure above.

fig. 3-2
 CHAPTER 1 TECHNICAL PARAMETER & SERVICE
SPECIFICATION

Vehicle specifications
Vehicle
mode
Item

Overall length
Overall width
Overall height
Wheel base
Tread (Front)
Tread (Rear)
Min ground clearance(Unloaded) mm
Kerb weight
Gross vehicle weight
Passenger

Vehicle specifications

Vehicle
mode
Item

Overall length
Overall width
Overall height
Wheel base
Tread (Front)
Tread (Rear)
Min ground
clearance(Unloaded) mm
Kerb weight
Gross vehicle weight
Passenger
Vehicle specifications
Vehicle
mode
Item
Overall length
Overall width
Overall height
Wheel base
Tread (Front)
Tread (Rear)
Min ground
clearance(Unloaded) mm
Kerb weight

Gross vehicle
weight kg
Passenger

Vehicle specifications
Vehicle mode
Item
Overall length
Overall width
Overall height
Wheel base
Tread
(Front)
Tread (Rear)
Min ground
clearance(Unloaded) mm
Kerb weight
Gross vehicle weight kg

Passenger
Parameter of wheel alignment angle
Table 1
Hatch back Sedan
Odd wheel
Caster wheel
Right-left
error
Odd wheel
Front Camber
Wheel
wheel
Right-left
error
Alignme King-pin Odd wheel
nt inclination wheel
Right-left
angle error
Toe-in

Rear Camber Odd wheel

Wheel wheel
Right-left
Alignme error
nt Toe-in

Wheel alignment check state specification

The center of mounting bolt The bottom of joint between
between lower arm and body longitudinal control arm and body

Table 2
Vehicle Front A(mm) 202±5
height Rear B(mm) 216±5
1. Adjust vehicle according to Table 2, and then measure parameter of wheel
alignment. The measurement should follow as specification in Table 1.
2. All vehicle types listed in this manual should be placed the same state,
when measuring parameter of wheel alignment.

Engine specifications
Engine ID TJ376QE TJ378QE CA3GA2
3-cylinder-in-line,
3-cylinder-in-line, water-cooling, water-cooling, 4-
Engine type 4-stroke, overhead camshaft, 6- stroke, double
vavle, EFI overhead camshaft,
12-vavle, EFI
Displacement L 0.993 1.052 0.993
Bore ×stroke mm 76×73 78×73.4 76×73
Max power kw/rpm 39/6000 42.5/6000 46/6000
Max torque N·m/rpm 77/3600 87/3600 89/3600
Idle speed rpm 880±50 880±50 850±50
Spark plug style F7RTC F7RTC K7RTC
Spark plug gap mm 0.7~0.8 0.7~0.8 0.7~0.8

Valve gap Intake 0.08~0.16 0.08~0.16 0.15~0.25

(cold) mm Exhaust 0.08~0.16 0.08~0.16 0.20~0.30
Drive belt of water pump
and alternator deflection 5~7/100 5~7/100 ------
mm/N

Engine specifications
Engine ID 8A 8A+ CA4GB1

4-cylinder-in-line, water-cooling, 4-stroke, double

Engine type
overhead camshaft, 16-vavle, EFI

Displacement L 1.342 1.425

Bore ×stroke mm 78.7×69 80.5×70

Max net power
--------- --------- 63/6000
kw/rpm
Max torque(net)
110/5200 --------- 110/2600~3000
N·m/rpm
Rating power
63/6000 68/6000 ---------
kw/rpm
Max torque N·m/rpm --------- 114/5200 ---------

Idle speed rpm 700±50 800±50

Spark plug style K16R-U K7RTC

Spark plug gap mm 0.8 0.7~0.8

Valve gap Intake 0.2±0.05 0.2±0.03

(cold) mm Exhaust 0.3±0.05 0.3±0.03
Drive belt of water pump New belt 7~9/98
and alternator deflection 7~9/98
mm/N Old belt 11.5~13.5/98

Belt of power steering New belt 5~6/98 New belt 5~6/98

deflection mm/N Old belt 6~8/98 Old belt 6~8/98
NOTE: New belt is that runs in engine in 5 minutes.
Old belt is that runs in engine over 5 minutes.

Maintain date
Engine oil
●Oil grade
TJ376QE/TJ378QE/
Engine ID 8A/8A+ CA4GB1
CA3GA2
SAE:10W-30 or SAE:10W-30 or
SAE:10W-30 or 5W-30 5W-30 5W-30
Oil grade
API:SJ or more than it API:SL or more API:SL or more
than it than it

●Engine oil viscosity should be suitable for the local environment; this is important for the
vehicle best performance and starting in winter. Please select Engine oil viscosity by the table
below.
Caution: When the oil grade is no higher than SAE 5W-20, do not run the engine
at the condition of opening throttle overall for a long time, especially when the
environment temperature is higher than the following temperature range.
● CAPACITY
2.8L (without replacing oil filter)
3.0L (with replacing oil filter)
●Using period 5,000km
Recommend Engine oil viscosity SAE NO.
Gasoline

● Specification
Unleaded gasoline with RON 93 or higher
Do fill EUIII (OBD) gasoline on the E3 vehicle.
COOLANT
●Specification
Recommend using glycol coolant; do forbid using ethanol coolant.
●Solidification temperature
The coolant that fills in vehicle cooling system, which solidification temperature is -
34℃; Customers can match the coolant according to local region lowest temperature.
●Capacity:
3.5L (with reserve tank)

●Replacement: One year

●Caution: Do not mix two different grade coolants.
Gearbox oil
● Grade API GL-4
● Viscosity SAE 80W-85(solidification temperature -26℃)
Specific cold region SAE 75W-85
● Capacity 2.1-2.25L

Brake fluid
Specification: JG4 accords with GB10830 or DOT4 accords with FMVSS

NOTE: Different brand fluids are forbidden to be mixed together

Replace the fluid once a year.

Tire
Type of tire 165/70R13
Pressure of tire kPa(kgf/cm2)
TJ7101 TJ7102 TJ7111 TJ7131 TJ7141
front 180(1.8) 200(2.0)
rear 180(1.8) 200(2.0)

Clutch pedal
Clutch pedal free travel 15-30mm

Break pedal
Break pedal free travel 3-7mm

Front break lining

Minimum limit 1.0mm

Rear drum break lining

Minimum limit 1.0mm

Steering wheel
Steering wheel free path 1 – 10mm
(Measure from the outer fringe of steering wheel)

Power steering fluid: Q/SAH·01-2006

(Manufacturer: Aogina, Shenyang)

Refrigerant
R134a

Front axle
Front hub bearing’s form is double row angular contact ball bearing, the tightening torque of front
axle nut is 166 - 225N·m.
Rear axle
The rear bearings of hatch back are two single row deep groove ball bearings, the tightening
torque of rear axle nut is 59 - 98N·m.
The sedan’s rear bearings are two single row tapered roller bearings. The preload of the inner and
outer bearing must be adjusted. Method as follow:
A．Screw down the nut gradually, eliminate the clearance between two bearings. In the progress
of screw down rotate the brake drum 2-3 times, make the roller assort properly with the bearing
out and inner rings. Screw down until the brake drum can not be rotated , now the torque
T≈30N·m。
B．Then loose the nut in reverse direction about 50-60 degree. To ensure the clearance between
the inner and outer bearings.( clearance ≤ 0.05mm). let the nut cap align the pin hole in the shaft.
C．Pack bearing grease between the rollers and rings of the inner and outer bearings; also pack the
grease in the grease retainer cap (about 1/3 dimension of the cap) and pack the grease in the lip of
the oil seal.
D．Install a new cotter pin, and lock.