2002 Mercury Marine 250 OptiMax Jet Drive Service Manual
This service manual covers the 250 OptiMax Jet Drive, detailing ignition, fuel system, powerhead, and pump unit components. Includes detailed diagrams and troubleshooting steps. Ref: 90-888438
Manual Preview
Sample pages from the 2002 Mercury Marine 250 OptiMax Jet Drive Service Manual manual
Purchase & Download
Mercury Models Covered & Key Technical Specifications
Models: Mercury Marine 250 OptiMax Jet Drive
Sub-models / Variants: 250 HP, 2-Cycle, Jet Drive, DFI, Inboard
Build Years: 2002
Serial Numbers: 0E407100 and higher
Technical Data:
- Horsepower: 250 HP (186.4 KW)
- Full Throttle RPM: 5375 ± 250
- Engine Displacement: 185.9 cu. in. (3047 cc)
- Configuration: V-6 Cylinder, Two Cycle
- Fuel System: Direct Fuel Injection (DFI)
- Fuel Pressure (Injectors): 90 ± 2 psi
- Air Pressure: 80 ± 2 psi
- Starter Draw (Under Load): 170 Amperes
- Spark Plug: NGK PZFR5F-11
- Charging System Output: 32–38 Amperes @ 2000 RPM
Mercury Manual Features & Content Preview
Mercury 250 OptiMax Jet Drive 2002 Service Manual
- Covers the 2002 Mercury Marine 250 OptiMax Jet Drive, documenting the V-6 DFI 250 HP engine system and jet pump installation
- Official Mercury Marine publication 90-888438, dated June 2002
- Contains 56 detailed diagrams and illustrations of engine components, electrical systems, and fuel delivery circuits
- Your order stays downloadable from your account for life
- Indexed PDF search covers every chapter and appendix
- Includes 12 torque specification tables and detailed electrical component data
- This official 2002 Mercury Marine service publication is the authoritative documentation used by dealer technicians for the 250 OptiMax Jet Drive system build
Documentation Scope
The 2002 Mercury Marine 250 OptiMax Jet Drive manual provides comprehensive technical guidance for maintenance, installation, and component diagnostics. The content begins with critical specifications for the engine block, fuel system, and ignition components, followed by routine maintenance schedules for 10, 50, and 100-hour intervals. Detailed sections clarify the operational requirements of the direct injection system, including air compressor parameters, fuel pump pressures, and electronic control module (ECM) functions.
The installation segment covers jet pump integration, including tunnel dimensioning and hull opening requirements. It further details exhaust system alignment, cooling system flushing procedures, and electrical harness connectivity. The document segments provide a clear reference for the fuel lift pump, steering gear, and throttle linkage setup.
Technical Reference and Data
Specifications are provided throughout the document to assist with unit identification and system calibration. Cylinder bore diameter for the 250 HP model is listed as 3.6265 inches (92.1131 mm) in the engine block section. Intake fuel line pressure is documented at 90 ± 2 psi (613.5 ± 13.8 kPa) in the fuel system data table. Regulator current draw is specified as 0.15 mA with the ignition switch off.
This 386-page official Mercury Marine workshop manual covers the 2002 250 OptiMax Jet Drive, documenting engine, jet pump, electrical, and fuel-injection specifications for the 0E407100 and higher serial number range. Reference only — always consult a certified technician before performing service on this equipment.
Document Reference: 90-888438, June 2002
Manual FAQ, Purchase & Download Details
Customer Reviews
Read what our customers say about this Mercury Inboard-Engines-Sterndrives manual and share your own experience.