2002 Mercury 240 EFI Jet Drive Service Manual

Mercury 240 EFI Jet Drive 2002 Service Documentation

• Covers 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 including detailed ignition circuit ohm tests, fuel system pressure charts, and electrical troubleshooting flow charts
• File link appears in your order confirmation straight away
• OCR text layer lets you jump to a torque spec by keyword
• Laid out for standard letter and A4 printing
• This 2002 factory publication serves as the primary technical reference for the 240 EFI Jet Drive, providing specific calibration values for the engine management and fuel delivery systems

Manual Content Summary

This documentation covers the essential information required for the care and installation of the 2002 Mercury 240 EFI Jet Drive. The manual begins with comprehensive specifications for the V-6 powerhead and pump unit, detailing 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 requirements for jet drive propulsion setups in varying hull constructions.

The document provides guidance on installation, including hull cutout dimensions for the pump unit, cooling system setup, and instrumentation wiring for tachometer and depth monitoring. Detailed troubleshooting sections describe 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, including fuel stabilization and engine flushing, are defined alongside instructions for dealing with complete water submersion.

Technical Data Highlights

Engine timing and fuel injection are managed by the Electronic Control Module, which is detailed alongside the diagnostic test values for the ignition system. The manual documents that ignition coil primary resistance should 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). Fuel line pressure for the 240 EFI Jet Drive 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. For professional-grade reference regarding what an OEM service publication covers, this manual acts as the factory source for technical values. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This 431-page 2002 Mercury 240 EFI Jet Drive service manual provides complete technical data, installation requirements, and diagnostic procedures for the 240 HP powerhead and jet pump unit.