2002 Mercury 240 EFI Jet Drive Service Manual (P/N 90-884822)

• Details 2002 Mercury 240 EFI Jet Drive configurations, including powerhead and pump unit mechanical and electrical system identification
• Official Mercury Marine publication P/N 90-884822, December 2001 edition
• Contains 431 pages of technical data, including ignition circuit ohm tests, fuel system pressure charts, and electrical diagnostic flow charts
• Serves as the primary factory reference for the 240 EFI Jet Drive, delivering specific calibration values for engine management and fuel delivery systems
• Explores comprehensive maintenance for seven critical systems: Wiring diagrams, SmartCraft instrumentation, Engine Guardian systems, exhaust emissions, Vapor Separator Tanks (VST), Throttle Position Sensors (TPS), and oil injection pumps
• Outlines step-by-step procedures for six advanced tasks: stator servicing, wear ring replacement, impeller clearance adjustment, pinion gear shimming, powerhead removal, and Bendix starter rebuilding

Manual Content Summary

This documentation provides the exact specifications required for the maintenance and installation of the 2002 Mercury 240 EFI Jet Drive. The manual opens with comprehensive data for the V-6 powerhead and pump unit, defining torque requirements for hardware and proper lubrication schedules for internal components. Subsequent sections outline the fuel and oil injection systems, electrical system components, and specific installation parameters for jet drive propulsion setups across various hull constructions.

By outlining step-by-step instructions for complex tasks—such as rebuilding the solenoid-driven Bendix starter, adjusting the reverse gate, setting the proper impeller-to-wear-ring clearance, and performing precise jet pump shimming procedures—this guide allows DIYers and technicians to confidently complete a repair without relying on expensive marine shop labor.

The document delivers clear guidance on installation procedures, including hull cutout dimensions for the pump unit, cooling system setup, and instrumentation wiring for the tachometer and depth monitoring. Detailed troubleshooting sections explain the use of the Digital Diagnostic Terminal (DDT) for testing ignition components, crank position sensors, and manifold absolute pressure sensors. Maintenance routines for off-season storage, such as fuel stabilization and engine flushing, are defined alongside protocols for handling complete water submersion.

Technical Data Highlights

Engine timing and fuel injection are managed by the Electronic Control Module, which is outlined alongside the diagnostic test values for the ignition system. The manual specifies that ignition coil primary resistance must be verified using an ohmmeter against the identified pin configurations on the coil pack. Spark plug gap requirements for the 2002 Mercury 240 EFI are strictly set at 0.040 in. (1.0 mm), and fuel line pressure is specified at 41–45 psi (283–310 kPa) for optimal performance. The cooling system maintenance preview includes specifications for flushing procedures and the operation of the automatic bilge siphon system.

Because working on high-pressure fuel systems and electrical components carries inherent risks, prioritizing personal safety and following proper technical procedures is critical. This manual acts as the primary factory source to ensure any hands-on work is guided by accurate, safe technical values. For professional-grade reference regarding what an OEM service publication covers, this 431-page guide supplies the complete installation requirements and diagnostic procedures for the 240 HP powerhead and jet pump unit, ensuring every repair is executed with factory precision.

Prioritize precision in your maintenance routine with the exact OEM calibration values designed specifically to keep your Mercury Jet Drive running safely.