DIY hover n5 engine repair

Attention! The manufacturer recommends removing the power unit upwards, having previously removed the gearbox. Have an assistant remove the engine. Please note that extreme care should be taken when removing the engine, as the gaps between the engine and the body panels are small and the unit itself is heavy.

1. Remove the battery.

3. Drain the oil from the crankcase and the coolant from the cooling system.

4. Remove the air filter with the inlet pipe hose.

5. Disconnect the front pipe with the bracket from the engine and lower it down a little so that its flange comes off the studs of the exhaust manifold.

5. Turn the throttle valve drive sector to the stop and disconnect the throttle valve drive rod from it.

6. Remove the two throttle control link bracket bolts.

7. Move the bracket aside, without disconnecting the rods from it, so that it does not interfere with the removal of the engine.

8. Unscrew the fastening nut and remove the terminal of the "ground" wire of the engine from the hairpin.

9. Disconnect the block with wires from the coolant temperature sensor by pressing the plastic clip.

10. Loosen the tightening of the clamps and disconnect the radiator outlet hose from the thermostat and the radiator inlet hose from the cooling jacket branch pipe.

11. Disconnect the wire from the coolant temperature gauge sensor.

12. Loosen the clamp and disconnect the heater supply hose from the water jacket branch pipe.

13. Disconnect the block with wires from the knock sensor or remove the sensor. To remove the sensor, unscrew the nut securing it and remove the sensor from the stud, leaving it on the wire harness.

14. Disconnect the connector with wires from the low-voltage terminal of the ignition module by squeezing out the plastic latch.

15. Disconnect the block with wires from the terminal "D" of the generator. Sliding the rubber cover, unscrew the nut and disconnect the wires from the contact bolt (terminal "B +") of the generator.

16. Disconnect the block with wires from the adsorber valve by squeezing the plastic latch.

17. Disconnect the oil pressure warning lamp sensor wire.

18. Loosen the clamp and disconnect the vacuum booster hose from the receiver connection.

19. Press the plastic latch and disconnect the block with wires from the idle speed regulator installed on the throttle pipe.

20. Loosen the clamp and disconnect the adsorber purge hose from the throttle fitting.

21. Disconnect the connector with wires from the throttle position sensor by squeezing out the plastic latch.

22. Unscrew the fastening nuts, keeping the hoses from twisting with the second wrench, and disconnect the fuel supply and drain hoses from the fuel pipes (the fuel supply hose is marked with paint). Note that O-rings are installed in the fuel pipes.

23. After disconnecting each hose, remove the O-ring from the tube (replace torn or loose rings).

24. Disconnect the heater outlet hose from the water pump inlet pipe. Disconnect the injector harness block by pressing the plastic catch. Disconnect the connector with wires from the crankshaft position sensor.

25. Disconnect the power steering pump and the air conditioning compressor from the engine, while do not allow the temporarily disconnected air conditioner and the power steering pump to hang on the hoses.

26. Recheck that all wires and hoses are disconnected from the engine.

27. Suspend the engine by hooking the cable onto the two eyelets and pulling it on with a hoist or crane.

28.If there is no hoist or crane, install a suitable board on the front fenders, placing soft gaskets under its ends so as not to spoil the paintwork, tie the engine to it by the eyelets using cables, ropes, etc. (they must be tensioned).

29. Remove the transmission with the transfer case.

30. Remove the two bolts securing the front suspension support of the power unit.

31. Lift the engine up and place it on strong supports so that the engine does not rest on the flywheel and alternator drive pulley.

32. Establish the engine in the reverse order of removal. After installation, add oil to the crankcase and coolant to the cooling system.

the block is not liner, the block is bored for repair liners; liners are pressed into the block, bored and honed under the piston. repair price was 15,000 rubles

on the block next to each sleeve the number 2 is driven in and on the piston the letter A
Sorry. I do not understand, everything is clear.

took a car in Moscow and this is 700 km

Out of topic! If you took it for cash, it is better to drive to Belarus, next to it is the Chinese assembly.
But it's good that the machine was cured, and repairs are somehow quite cheap. I wish you many hundreds of thousands without breakdowns!

I did the repair myself, except of course the sleeve, this amount with all consumables.

Well for golden hands

And people charge 60,000 for replacing the cylinder head gasket.

Good day. I got the hover in March 2013, of the problems - engine overhaul, block liner. I did not go to MOT because the price for MOT was turned down in the service -0 17,000 rubles. without consumables, referring to the fact that the car was not purchased.

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One of the specializations of our stations is the high-quality repair of Great Wall Hover H5. Our auto repair shops have a dedicated repair tool for Great Wall Hover H5. Consumables, oils and fluids are available for routine maintenance. Within a couple of hours, from the main warehouse, we will bring any spare parts for repairing Great Wall Hover H5.

Before starting repairs to Great Wall Hover H5 we will make free diagnostics suspension, engine or electrics (free diagnostics in case of repair at our service stations). We do not recommend doing DIY repairs on your Great Wall Hover H5. Everyone must do their job. You need to entrust the repair of your car to those who do it every day.

The cost of repairing Great Wall Hover H5:

Routine work and maintenance of the Great Wall Hover H5 is recommended to be carried out every 7-10 thousand km. mileage. This necessarily includes changing the engine oil, oil filter, air filter and cabin filter. When carrying out scheduled work, we will make free diagnostics of all vehicle components and draw up a list of recommendations.

Every 60 thousand km. mileage, we recommend changing the timing belt with rollers, and if the motor is chain, then it is better to replace the chain every 120 thousand km. It is better to replace the candles every 40 thousand kilometers on gasoline engines and 100 thousand kilometers. mileage on a diesel engine. On Great Wall Hover H5 models with adaptive throttle, it is recommended to clean and adapt the throttle every 60,000 km.

The most famous problems and malfunctions of the Great Wall Hover H5:
- acidification of the caliper pistons with subsequent uneven wear of pads and discs;
- unsuccessful design of the fuel filter - the car jerks, stalls, troit;
- creak in the car interior due to low-quality plastic - gluing with anti-creak material;
- a problem with the box - early failure of bearings and primary shaft oil seals;
- in standard cooling radiators, leak at the junction with the side part;
- tight steering wheel - a problem with the power steering of the car - a bulkhead or replacement, according to the result of diagnostics.

The degree of wear of the Great Wall Hover H5 hub bearing can only be determined by diagnosis.

Warranty for all repair work Great Wall Hover H5 - 6 months.

Japanese gasoline engines 4G63S4M, 4G64S4M, 4G69S4N installed on Mitsubishi found their application on Hover. The diesel GW4D20 is a proprietary engine, as well as the transmission. The advantages and disadvantages of this machine are quite subjective. "What is good for a German, death for a Russian." For those who are used to driving with a breeze, the Hover is clearly not suitable. Well, it does not accelerate, there is not enough power, it is rather weak.

But is this characteristic a disadvantage? We will look for the answer in the instructions for use and maintenance, where it is indicated that the maximum speed for a gasoline engine is 100 km / h, and for a diesel one, 90 km / h. So needless to say that it does not pull. He who is forewarned is armed. The frame structure of an SUV with engine displacement of 2.0 and 2.4 does not provide for cross-country racing.

The transmission of our own production is designed to work in tandem with the engine. When trying to accelerate and ask for more horsepower than it is, the gearbox is experiencing serious stress, which leads to premature wear of both the box itself and the power unit. When commissioning a new Great Wall Hover, it is necessary to observe the break-in mode, which is 1000 km for gasoline 4G63S4M, 4G64S4M, 4G69S4N, and 1500 km for diesel GW4D20. The same requirement applies to overhauled engines. When the all-wheel drive is turned on, the permissible travel speed is: 4H-40 km / h, 4L-30 km / h. At the same time, the use of 4WD is allowed only on slippery roads and in a straight line. Failure to comply and ignorance of these rules leads to problems in the box, axles and transfer case.

To increase the service life and resource, it is necessary to comply with the maintenance regulations and operating rules:

• Observe the speed limit.
• Check oil level daily.
• Change the engine oil every 8000 km. mileage.
• In winter, start driving after warming up.
• Do not run the diesel engine at idle speed for more than 20 minutes, avoid traffic jams.
• Use only high quality fuel.
• After long trips, do not turn off immediately, let it cool down with the engine running.
• Do not use the machine to transport heavy items.

All the rules are written in the instruction manual. And unfortunately, some of them are simply unrealistic to fulfill due to subjective and objective reasons.

Life can be prolonged with the help of RVS Master tribotechnical compounds. By virtue of their properties and principle of action, which is based on the chemical reaction of replacement of iron atoms with magnesium atoms, they are rightfully called repair and reduction compositions. The reaction is possible only if there is: a cast-iron block for the engine from which the Hover is made; ferrous metals used in the manufacture of bearings, gears and transmission shafts. As a result of the use of the tribotechnical composition RVS-Master, a cermet layer is formed on the friction surfaces that are subject to wear. And this is not a temporary film, as is the case with oil additives. In addition, a constant presence in the oil is not required. One or two treatments are enough, depending on the degree of wear, to increase the resource up to 120 thousand km. mileage. Repair and restoration compositions allow:

• Restore compression
• Reduce oil consumption
• Increase power and throttle response
• Stabilize idling
• Restore the contact patch on the gear teeth
• Protect against wear
• Facilitate cold start
• Reduces noise and vibration in both the motor and transmission
• Easy and smooth gear shifting without kicks and bumps

The capabilities of tribotechnical compositions are due to the characteristics of the newly formed cermet layer, which has an abnormally low coefficient of friction, is resistant to shock loads and is plastic, protects against oxidation and corrosion. As it wears out, the layer can be restored by repeated treatments.

For gasoline engines 4G63S4M, 4G64S4M, 4G69S4N, the GA4 composition is suitable, calculated for 4 liters of oil.

For diesel GW4D20 - composition DI6, designed for 6 liters of oil.

Despite the fact that the volume of transmission oil in the gearbox is 3.0 liters, the front axle is 1.8 liters, and the rear axle is 2.7 liters, we recommend using the above compositions.

It is recommended to use at least AI-93 gasoline and only good quality diesel fuel. Such requirements are indicated in the vehicle specifications. The use of fuel with a low octane and cetane number leads to detonation, the power of the already non-thrust engines decreases, and consumption increases. In addition, the content of impurities in low-quality fuel accelerates the process of mechanical wear of the power unit parts. Particularly sensitive is the GW4D20, which is equipped with a Common Rail injection system.

The use of low quality diesel fuel leads to incomplete combustion, which in turn makes it difficult to start the diesel engine in cold weather, the formation of carbon deposits in the combustion chamber, on rings and injectors, and as a result, the appearance of black smoke from the exhaust pipe. The high sulfur content in diesel fuel together with condensate form sulfuric acid, which causes chemical corrosion of the cylinder walls of the Hover engine and pistons. Ultimately, the above reasons lead to failure of the fuel pump, fittings, and the power unit itself.

To protect against low-quality fuel, we recommend using the FueleXx combustion catalyst. It provides more complete combustion and helps protect the vehicle from the above problems.

For used Great Wall Hover machines, we recommend flushing the injector and cleaning the nozzles with the following agents:

Injector Cleaner Ic for gasoline 4G63S4M, 4G64S4M, 4G69S4N

• Rebuild spray torch
• Normalize idle speed
• Eliminate dips and jerks during acceleration
• Normalize acceleration dynamics
• Reduce consumption
• Compensate for the lack of lubricants in the fuel
• Remove carbon deposits from injector
• Restore line pressure

The formulations do not contain chemical solvents and do not lift dirt from the tank, do not change the composition and properties of the fuel.

The principle of operation and maintenance is no different from the hydraulic boosters of other car brands. But the build quality and seals are poor. In case of leakage and leakage of liquid through the seals and oil seals, which can occur on a new car, it may be sufficient for the whistling and hum of the power steering pump to appear. What to do if the warranty repair was denied? Timely use of the Power Steering Ps2 for the restoration of the power steering pump will allow restoring the linear dimensions of the parts, reducing the gaps on friction pairs, as a result, removing the hum and howling, and making the steering wheel light.

Repair and reduction compositions - a new technology in repair, reliable protection against wear and an increase in the resource of units and machines.

From the history of the model

ENGINES: petrol - P4, 2.0 l, 122 hp; 2.4 l, 130 and 136 hp; diesel - P4, 2.0 l, 150 hp; 2.8 L, 95 HP

• 2010 - changed bumpers, radiator grill and lighting equipment; redesigned interior; transfer case control became electronic;

• 2011 - the front part was completely changed: bumper, fenders, lighting equipment and radiator grill; redesigned rear: bumper and trunk lid; appeared "machine".

• 2007, Hover H2, C-NCAP method: overall score - three stars, frontal impact - 10 points (63%), frontal impact with 40% overlap - 12 points (77%), side impact - 15 points (92%);

• 2010, "Hover H3", Dmitrovsky polygon, Euro NCAP methodology: overall rating - four stars, 11.7 points out of 16 possible (73%);

• 2011, "Hover N5", Dmitrovsky proving ground, Russian methodology - the Chinese off-road vehicle meets all safety requirements in force on the territory of the Russian Federation.

The Chinese have mastered the cloning technology quite well, and in the case of the Hover, no gene mutations have occurred. The twin of the Japanese "Isuzu-Axiom" turned out to be quite nice and solid. Initially, the car was made only in China, but already in April 2010, assembly was established in Gzhel near Moscow. The Russian VIN is located under the hood, on the engine shield on the left, the Chinese one is stamped on the frame, behind the rear right wheel, when registering it is entered simply as a frame number. Our build, unfortunately, does not differ for the better. The body parts are poorly fitted, and already in the service it is necessary to finish the car, eliminating unacceptably large gaps. There have been cases when, due to careless assembly in the cabin, leaks appeared along the openings of the rear doors and the trunk lid.

The Hover's body paint is not famous for its high quality, but it also has no serious flaws. The biggest problem was the appearance of rust under the cover of the fifth door due to the poor design of the latter. But it was changed already at the first restyling. The metal of the body is not galvanized, but with proper care it will at least hold up.

Great Wall Hover Time-tested Mitsubishi 4G petrol engines look about the same.

Gasoline engines are borrowed from Mitsubishi and can be found on Pajero and Outlander. The first Hovers H2 even retained the symbols of the Japanese manufacturer under the hood. All motors are reliable and maintainable. However, when adjusted to modern toxicity standards, they lost their dynamics. Although the Japanese, under the same restrictions, remove much more from their engines.

A strange thing, during the first modernization ("Hover N3"), the 2.4 liter engine (4G64 with 130 hp), which frankly did not pull, was replaced with an even less powerful 2-liter (4G63, 122 hp). During the second work on the errors ("Hover H5"), the old displacement returned (4G69, 136 hp), but did not add enthusiasm. To help the owners, some services offer a flashing of the control unit. The service is efficient and highly demanded.

Great Wall Hover The Chinese supercharged diesel engine has not yet earned any complaints. Apparently, due to the fact that it was developed together with the Germans.

Contrary to the permission to use 92nd gasoline, it is recommended not to save and pour 95th - because of the tendency of the engine to detonate. Fuel consumption can be considered adequate to the engine displacement and the weight of the car. You shouldn't save on oil changes either. Since this year, the manufacturer has reduced the interval between maintenance to 8000 km, and this is quite justified, especially when operating the Hover off good roads. Most of the malfunctions are supplied by the motor equipment. Most often, the crankshaft sensor and lambda probes fail. In the first case, the problem is in the quality of the unit, and in the second, half the battle is in our gasoline. Sometimes there is a malfunction of the idle speed regulator, otherwise there are no more defects than those of well-known manufacturers.

Great Wall Hover It is not possible to reprogram the ECM via the diagnostic connector, you need to connect it directly.

There are no complaints about diesel engines. A very rare atmospheric volume of 2.8 liters migrated from the Axiom and is found only on pre-styling H2 models. The supercharged 2-liter diesel is already a joint German-Chinese development, but it became available only on the H5. With its high reliability, the new diesel, unfortunately, is no less lazy than the gasoline brothers. A significant turbo lag is released only after 2000 rpm, which is extremely uncharacteristic for diesel engines. But here, too, a flashing will come to the rescue.

The manual transmission is quite reliable. She suffers mainly due to unprofessional tuning. When installing additional protection, its airflow is disrupted, causing overheating, from which the bearings primarily suffer. The same is observed if the oil change intervals are not followed.Fortunately, the box is structurally simple and maintainable.

Great Wall Hover Only thanks to perseverance, the marriage of the internal CV joint anthers was recognized as factory and they were changed under warranty.

The clutch is not known for its high reliability. The average lifespan is about 80,000 km, and that is greatly reduced when driving off-road. You will find reinforced analogues on the spare parts market. They will last longer, but the switches will become more rigid. At one time on the H5 there was a defect in the clutch basket, which is why the gears turned on poorly on a warmed-up car. On some Hovers, the clanging of the release bearing could be heard. For reasons unclear until the end, his body touched the petals of the basket. The defect is treated by replacing the assembly with a selective selection of parts. There is a slight adjustment of the pedal travel, but contrary to rumors, this operation does not significantly affect the life of the linings.

Aisin automatic transmission is only available on the H5 with a diesel engine. There are no problems with it.

There are also no additional recommendations for maintenance, except for observing the oil change intervals.

The transfer case control lever on H2, when switching to the H3 model, gave way to a button (it is also found on the transitional H2).

Great Wall Hover The oxygen sensor is the second most failure rate in the engine. Most often, bad gasoline shortens its life.

On all Hovers, the front axle is engaged through an electronic clutch that controls the connection of the left wheel shaft to the front differential output shaft. With the clutch disengaged, free rotation of the front right wheel causes free rotation of the differential, as a result of which other transmission elements do not rotate.

The all-wheel drive activation sensor most often becomes the culprit of malfunctions - the impossibility of connecting or spontaneous blocking of the clutch.

The mechanical part of the all-wheel drive does not cause problems. Servicing the transfer case is reduced to a timely oil change. The bridges are reliable and designed for increased loads. The main thing here is to comply with the service regulations. There was a period when there was a factory marriage of the internal anthers of the CV joints. For no apparent reason, holes appeared into which the grease was squeezed out. Timely replacement of covers helped.

Great Wall Hover Usually there is no clutch kit as such, each item comes separately. There are reinforced options.

On the market there are spare parts for fine-tuning the model: other main pairs, differentials with locking. Some services offer to raise the body. But even without fine-tuning, the off-road capabilities of the Hover meet the expectations of most owners.

The Hover boasts a frame structure and reliable suspension. The only reason for criticism is the rear shock absorbers on the restyled H3 and H5. Owners complain about their excessive rigidity, which causes the rear of the car to bounce on bumps. But you can choose softer analogs. The silent blocks of the front upper levers travel 80,000 km, and the lower ones - about 100,000. Balls serve about 60,000 km and usually die in pairs. Rear suspension silent blocks live approximately 100,000 km.

Great Wall Hover It happens that the original Chinese pads squeak when working. But there is a large selection of analogs.

The braking system is poorly calculated. Due to the heavy weight of the car, the pads wear out very quickly: the front ones take 20,000 km, and the rear ones take 35,000 km. At the same time, the front brake discs are enough for 80,000 km, and the rear ones are rarely changed at all. With heavy use, the brakes sour already by 20,000 km. It is worth doing their prevention every time you change the pads. Steering malfunctions are found mainly on pre-styling H2. By about the age of five, the power steering pump may fail. The lower steering cardan connecting the bevel gear and the rack is also weak. On the H3, this design was abandoned. The racks rarely break, and the tie rods and tips are changed separately.

Great Wall Hover Monroe rear shocks are one of the softer counterparts. With them, the rear of the car no longer bounces on bumps.

It is recommended to renew the oil in the amplifier more often, the interval depends on the operation.

At first, the salon almost completely migrated from the Axiom. But during the modernization on the N3, they introduced their own version. Although sometimes there are transitional H3s with an old interior. Internal electrical equipment has a separate control unit. Because of his freelance work, the electrician sometimes went crazy. Under the recall campaign, this block was reflashed.

Great Wall Hover The owners have nicknamed this salon "the fifth". It appeared during the first restyling, and opinions were divided: some people prefer the old Isuzu salon.

The disadvantage of the air conditioning system was the lack of a cabin filter (until this year) and the location of the lower pipe of the refrigerant line, which suffers from reagents. The radiator of the stove requires attention - it sometimes flows on old H2.

The rain sensor can cause damage to the wipers. In winter, when the wiper blades stick to the glass, it cuts off the splines on the leashes due to its operation. Plastic bushings often break in the mechanism; to replace them, you will have to completely disassemble the trapezoid.

Great Wall Hover The lack of a cabin filter made life difficult for the owners. The installation operation is laborious, but proven and inexpensive.

The lock of the regular gas tank cap often fails, so the owners change the obstinate cap to a regular one - without a larva.

There are still problems with spare parts in the regions. The Chinese have not made normal catalogs, which is why it is difficult to select parts, and difficulties with delivery do happen. Sometimes it is possible to adapt analogs from other brands, but some have no alternative.

"Hover" is notable for its maintainability, so that an experienced owner will cope with routine maintenance.

If you do not save on maintenance and pay attention to the "Hover" according to the regulations, then the label "Made in China" can be regarded as a compliment.

Thank you for your help in preparing the material.

• Dollar - 58.85 rubles.
• Euro - 62.68 rubles.

This manual covers the operation and repair of the Great Wall Hover H5 / Haval H5 (Great Wall Hover H5 / Hawal H5), manufactured since 2010. The book describes the repair of cars with gasoline and diesel engines 4G64S4M / GW4D20, volume 2.4 / 2.0D liters.

Publisher: Monolith
Cover: soft
Format: A4
Number of pages: 380
Paper type: newspaper
ISBN: 978-617-537-109-1

Engine's type: 4G64S4M / GW4D20
Engine capacity: 2.4 / 2.0D L
Power: 136/150 HP

Introduction
Emergency response
Daily checks and troubleshooting
Car operation in winter
A trip to the service station
Vehicle operation and maintenance manual
Precautions and safety rules when working on a car
Basic tools, measuring devices and methods of working with them
The mechanical part of the diesel engine 4D20
The mechanical part of the petrol engine 4G69S4N
Cooling system
Lubrication system
Supply system
Engine management system
Intake and exhaust system
Engine electrical equipment
Clutch
Gearbox ZM001DB / ZM001DF
Manual transmission 038M1 / 038M
Manual transmission 5DYG / 5DYM26
Manual transmission ZM016B / ZM016BF
Automatic transmission 5R35
Transfer case
Drive shafts and axles
Chassis
Brake system
Steering
Body
Passive safety
Air conditioning system
Vehicle electrical equipment and wiring diagrams
Dictionary