2002 Mercury 150 EFI / 175 EFI / 200 EFI Outboard Service Manual

2002 Mercury 150/175/200 EFI Outboard service manual covering troubleshooting and maintenance procedures. Publication 90-883728.

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Document Details

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Document Number / Seller:
27230 / Richard Owens
File Size:
16.77 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Mar 9, 2025

Models Covered & Key Technical Specifications

Mercury 150 EFI / 175 EFI / 200 EFI (2002) Outboard Service Manual Complete guide for your Mercury outboard.

  • Verified Throughput Data: 650 ± 50 RPM establishes the minimum idle engine speed Framework.
  • Key Angular Speed: 5250 – 5750 RPM is the recommended wide-open-throttle range Architecture.
  • Principal Package Size: 1.0 mm is the standard spark plug gap Norms.
  • Advanced Moment Values: 0.19 – 1.0 VDC signifies the idle throttle position signal Topology.
  • Designated Fit Tolerances: 143°F (61.7°C) is the operating temperature for the thermostats Matrix.
  • Designated Speed Rating: 41 N-m controls the torque for the starter motor assembly Standards.

Professional Workshop Service Manual & Technical Specifications

Technical Troubleshooting Field Manual: Outboard Motor Comprehensive Mercury 150 EFI, 175 EFI, 200 EFI Outboard Service Manual (2002) Powertrain-Manual

Operational-Framework: 2002 // Machine-Range: Mercury Outboard Motor / EFI // Operational-Framework: 2002

Integrated-Framework Technical-Path Calibration-Spec
Specifications Ignition Coil Ohms Test Manifold Absolute Pressure (MAP) Sensor Ohms Test
Port and Starboard Temperature Sensors; Air Temperature Sensor Special Tools Coil Plate Assembly
Electrical Plate Assembly Theory of Operation Ignition Component Description

Reference chapters include: Ignition Coil Ohms Test, Manifold Absolute Pressure (MAP) Sensor Ohms Test, Port and Starboard Temperature Sensors; Air Temperature Sensor, Special Tools, Coil Plate Assembly, Electrical Plate Assembly, Theory of Operation, Ignition Component Description, Fuses, Charging System Alternator, Ignition Coil, Electronic Control Module, Flywheel, Crank Position Sensor, Throttle Position Sensor (TPS), Throttle Position Sensor (TPS) Troubleshooting, Cylinder Head Temperature Sensor, Air Temperature Sensor, Port and Starboard Temperature Sensors; Air Temperature Sensor, Manifold Absolute Pressure (MAP) Sensor, Ignition Troubleshooting and Fault Chart, Ignition Coil Ohms Test, Manifold Absolute Pressure (MAP) Sensor Ohms Test, Idle Speed Control, RPM-Limit Circuit, EFI Detonation Control System (200 Model only), Detonation Circuit Test, Troubleshooting, Troubleshooting Without Digital Diagnostic Terminal, Troubleshooting with the Digital Diagnostic Terminal, Notes, DDT Functions – EFI Models.

Carefully requiring the ECM to monitor critical engine functions and reduce engine power to maintain safe operating parameters, this manual documents the "Engine Guardian System". Diagrams are provided for component identification and troubleshooting procedures.

This manual documents torque specifications for engine components to ensure proper seal compression uniformity.

FAQ

What is the **required** fluid capacity for the gear case? keyboard_arrow_down

22.5 fl. oz. (717 ml) is the gear case lubricant capacity for both the 1.87:1 and 2.00:1 gear ratios.

Calculate the **specified** spark plug gap for the ignition system. keyboard_arrow_down

0.040 in. (1.0 mm) is the specified spark plug gap for the Digital Inductive ignition system.

What **essential** adjustment procedures are documented for the throttle cable? keyboard_arrow_down

0.005 in. to 0.020 in. (0.13 mm to 0.51 mm) is the essential clearance that should exist between the roller and throttle cam after adjusting the idle stop screw.

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Reviews (5)

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The download process was smooth, and I received quick responses to my questions. Very professional service!
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Rated 4 out of 5 stars
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Covers everything you need to know about maintenance and troubleshooting. Worth every penny!
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This manual is incredibly detailed and easy to follow. The diagrams are a lifesaver!
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The step-by-step guides made my repairs straightforward. Highly recommend it!