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MerCruiser GM4 manuals

Owner’s manuals and user’s guides for Engine MerCruiser GM4.
We providing 1 pdf manuals MerCruiser GM4 for download free by document types: Service Manual


Mercruiser GM4 Service Manual (422 pages)


Brand: Mercruiser | Category: Engine | Size: 5.64 MB |

 

Table of contents

Number 26

1

90-861329--1

2

Engine Mechanical Components

4

Replacement Parts

4

Models Covered in This Manual

4

Service Manual Outline

5

Introduction

8

How to Use This Manual

8

How to Read a Parts Manual

9

POWER STEERING PUMP ASSEMBLY

9

Directional References

10

Engine Rotation

10

Propeller Information

11

Water Testing New Engines

12

Boat and Engine Performance

12

GENERAL INFORMATION

13

Marine Fouling

14

Weight Distribution

15

Water in Boat

15

Elevation and Climate

15

IMPORTANT INFORMATION

17

Maintenance Schedule

18

MAINTENANCE

19

Fluid Capacities

21

20-Hour Break-In Period

21

After Break-in Period

22

End of First Season Checkup

22

Gasoline / Alcohol Blends

23

Boat / Motor Storage

24

Winter Storage

24

Warranty

24

Continuing Evaluations

24

Crankcase Oil

25

Adding Crankcase Oil

26

Changing Oil and Filter

27

Priming Engines With Oil

27

Power Steering System

28

Filling and Bleeding

29

Closed Cooling System

30

Flushing System

31

BOAT IN WATER

32

Lubrication

33

Shift Cable

34

Power Package Layup

36

Used Spark Plug Analysis

49

Spark Plug Analysis

50

Cold Fouling

51

Overheating

51

High Speed Glazing

51

Scavenger Deposits

52

Pre-Ignition Damage

52

Reversed Coil Polarity

52

Splashed Deposits

53

Mechanical Damage

53

RPM Too High

55

RPM Too Low

55

Important Information

56

EST Ignition System Check

57

Ignition System Check(1 of 2)

58

Charging System Inoperative

60

Noisy Alternator

61

Fuel System Rich

61

Fuel System Lean

62

Carburetor Malfunction

62

Engine Runs Poorly At Idle

64

Engine Acceleration Is Poor

65

Poor Fuel Economy

66

Radio Noise

67

Miscellaneous

67

Instrumentation Malfunction

68

Engine Noise

68

Valve Cover Area

69

Cylinder Area

69

Camshaft Area

69

Crankshaft Area

70

Low Oil Pressure

73

High Oil Pressure

73

Excessive Oil Consumption

74

Water in Engine

75

Water On Top Of Pistons

76

Engine Overheats

77

Cooling System

78

Power Steering

79

Noisy Pump

80

Fluid Leaks

80

Seawater Pickup Pump

81

REMOVAL AND INSTALLATION

83

Lubricants/Sealers/Adhesives

84

Engine Removal

85

Engine Alignment

93

Engine Connections

95

SERVICE MANUAL NUMBER 26

101

Table of Contents

103

Table of Contents (continued)

104

Torque Specifications

105

Special Tools

106

Engine Specifications

107

Lubricants/Sealants/Adhesives

107

Piston Ring: Oil

108

Piston Pin

108

Crankshaft

108

Camshaft

108

Cylinder Head

109

Valve System

109

Engine Identification

110

Priming Engine With Oil

111

Bearing Failures

112

Improper Seating

113

Fatigue Failure

113

Piston Failures

114

Detonation

115

Engine Mounts

116

Rocker Arm Cover

117

Push Rod Cover

118

Rocker Arm/Push Rod

119

Valve Adjustment

120

Engine Running

121

Hydraulic Valve Lifters

122

Cleaning and Inspection

123

Installation

123

Disassembly

128

Cleaning

128

Inspection

129

Rocker Arm Studs

130

Valve Guide Bore Repair

131

Valve Seats

132

Reassembly

133

Dipstick Specifications

135

Oil Pump

137

Torsional Damper

139

Crankcase Oil Seal

141

Crankcase Front Cover

142

Flywheel and Engine Coupler

143

Rear Main Oil Seal

145

Main Bearings

146

Checking Clearances

147

Main Bearing Replacement

148

Connecting Rod Bearings

149

Inspection and Replacement

149

PISTON RINGS

154

Crankshaft Sprocket

159

Camshaft Gear Replacement

162

Camshaft Bearings

164

Cylinder Block

166

CYLINDER CONDITIONING

168

CYLINDER BORING

168

CYLINDER HONING

169

PISTON SELECTION

170

Oil Filter By-Pass Valve

171

ELECTRICAL SYSTEM

175

Identification

176

Replacement Parts Warning

176

Battery Cable Recommendations

177

Starting System Components

178

Positive Current Flow

182

Charging Guide

183

Slave Solenoid Identification

184

Solenoid Switch

185

Periodic Inspection

185

PG260 Starter Motor

186

PG260 Exploded View

187

Starter Motor Repair

188

STARTING SYSTEM

189

Armature Tests

193

Gear Bearing

194

Shaft Assembly Bearing

195

Drive End Housing Bearing

195

Brushes and Brush Holder

196

Starter Solenoid

202

PG260F1 Starter Motor

205

Exploded View

206

Specifications

222

Description

223

Precautions

224

Cleaning And Inspection

225

Distributor Installation

226

Ignition Timing

227

Component Tests

230

Testing Ignition Coil

231

Testing Pickup Coil

231

Advance Curve

233

Initial Timing 1° ATDC

234

Initial Timing 2° ATDC

235

System Components

241

Periodic Maintenance

242

Drive Belt Tension Adjustment

243

Circuitry Test

244

CHARGING SYSTEM

245

Current Output Test

246

Voltage Output Test

247

Alternator Repair

248

Component Testing

255

Batteries

265

Mando 55 Amp Alternator

266

Battery Isolator Diagram

268

Mando 65 Amp Alternator

269

Special Information

275

QSI SERIES

276

IndexIndex

276

Oil, Fuel and Temperature

277

Battery Gauge

279

Cruiselog Meter

280

Vacuum Gauge

280

Speedometer

281

Tachometer

281

Gauge Replacement

281

Oil Pressure

282

Water Temperature Sender

283

140°F (60°C) 121-147

284

194°F (90°C) 47-55

284

212°F (100°C) 36-41

284

INSTALLATION

285

Fuel Tank Sender

286

Capsule Type

287

Switches

288

Audio Warning System

289

Oil Pressure Switch

290

Water Temperature Switch

290

INSTRUMENTATION

291

Wiring Diagrams

296

A - Ignition Components

297

C - Audio Warning Components

297

10 RED GXL

300

8 RED–PPL

300

WIRING DIAGRAMS

301

PRIMARY STATION

304

SECONDARY STATION

304

Battery Meter Gauge

306

Cruiselog

306

Fuel Gauge and Sender

307

Water Temperature Gauge

308

Oil Pressure Gauge

309

FUEL SYSTEM

311

Lubricants/Sealants

313

Fuel Delivery System

315

Fuel System Components

316

Water Separating Fuel Filter

316

Replacement

317

Testing Fuel Pump

319

Fuel Pump Replacement

320

FUEL PUMP

321

Important Service Information

327

Needle/Seat Change

328

Maintenance

330

Fuel Inlet Filter

331

Adjustments

332

MERCARB 2 BARREL CARBURETOR

333

Choke Setting

334

Final Idle Speed and Mixture

335

Exploded View Parts List

339

FLOAT DROP

354

COOLING SYSTEM

359

Flushing Cooling System

361

Thermostat

363

Draining Instructions

366

SEAWATER COOLED MODELS

367

STANDARD DRAINING PROCEDURES

368

Recommissioning

370

Cooling System Flow Diagram

374

Coolant Recovery Bottle

379

Pressure Cap Maintenance

380

Heat Exchanger Repair

381

Testing Closed Cooling System

381

Testing Heat Exchanger

383

Testing Pressure Cap

383

Changing Coolant

387

SINGLE POINT DRAIN SYSTEM

388

CLOSED COOLED MODELS

389

Draining Diagram

390

Cleaning System

391

EXHAUST SYSTEM

399

Exhaust System

400

MANIFOLD

403

Emissions Testing

405

POWER STEERING

407

With Cold Engine

409

With Warm Engine

410

POWER STEERING PUMP

411

Pump Pulley Replacement

412

System Flow Diagram

420

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