Mercury 40 HP EFI 4-Stroke 2002–2006 Service Repair Manual – PDF Download

🛠️ Mercury 40 HP EFI 4 Stroke 2002–2006 Service Repair Manual – PDF Download

🧰 OEM Factory Workshop Manual – Covers Mercury 40 HP EFI FourStroke Outboard Engines (Serial No. 0T409000 and up)
📲 Instant PDF Download – Compatible with Windows, macOS, iOS, Android, and Linux
🔧 Used by Mercury-certified marine technicians, boat owners, and professional repair shops worldwide

🔍 Model Background

The Mercury 40 HP EFI 4-Stroke outboard (2002–2006) marked a key advancement in mid-range outboard technology. Built during Mercury’s engineering partnership with Yamaha, this model used a reliable 996cc inline-3 four-stroke engine and introduced Electronic Fuel Injection (EFI) to improve cold starts, throttle response, and overall fuel economy.

Designed for small boats like aluminum fishing rigs, pontoons, and inflatables, this engine featured a single overhead camshaft (SOHC), oil-bathed cam design, and mechanical throttle and shift. The result was a smooth, quiet engine that was easier to maintain than traditional 2-stroke options, while also meeting stricter emissions standards.

Though slightly heavier than the 2-stroke 40 HP models it replaced, the 2002–2006 EFI 4-Stroke earned a reputation for durability, fuel efficiency, and low vibration. It was eventually succeeded by Mercury’s fully in-house 40 HP EFI platform starting in 2007, but this generation remains well-supported and is still in service worldwide.

📆 Model Years Covered:

• Mercury 40 HP EFI – 2002
• Mercury 40 HP EFI – 2003
• Mercury 40 HP EFI – 2004
• Mercury 40 HP EFI – 2005
• Mercury 40 HP EFI – 2006

📘 Manual Details:

• Model: Mercury 40 HP EFI FourStroke (3-cylinder)
• Serial Numbers: 0T409000 and above
• Document ID: 90-883064R02
• Document Type: OEM Service & Repair Manual
• Language: English
• Publisher: Mercury Marine
• Pages: 600+ with step-by-step repair procedures and wiring diagrams

📚 Manual Sections Include:

• General Information & Specifications
• Ignition & Charging System
• Ignition coil, ECM, stator, flywheel, voltage regulation
• Fuel System
• EFI components, fuel pump, pressure testing, injectors
• Powerhead
• Pistons, crankshaft, camshaft, cylinder head, valve adjustment
• Cooling System
• Impeller, thermostat, water passages, flush procedures
• Midsection & Exhaust
• Driveshaft housing, exhaust routing, vibration mounts
• Gearcase Assembly
• Propshaft, shift rod, seals, water pickup, gear lubrication
• Control Linkage & Adjustment
• Throttle/shift cables, idle RPM tuning
• Wiring Diagrams
• Full EFI and ignition schematics with color-coded component references

💾 Format & Compatibility:

• File Format: PDF
• Searchable & Bookmarked: ✅ Yes
• Printable: ✅ Yes – Print full manual or selected chapters
• Compatible With: Windows, macOS, iOS, Android, Linux
• Delivery: 📩 Instant Digital Download

🔍 Keywords:

Mercury 40 HP EFI FourStroke service manual PDF, 2002–2006 repair guide, 4-stroke outboard, EFI diagnostics, valve lash, wiring schematics, OEM repair manual

❓ Mini FAQ:

Q: Is this the complete factory repair manual?
A: Yes – it’s the OEM Mercury manual used by authorized marine service professionals.

Q: Does this cover full EFI diagnostics and wiring?
A: Absolutely – detailed electrical and fuel schematics are included for all systems.

Q: Is the PDF mobile-friendly?
A: Yes – works on all smartphones, tablets, and computers with full search features.

🧭 Helpful Resources for Mercury Outboard Owners

• Why Every Mercury Mariner Owner Needs a Service Manual for At-Home Repairs – Learn how a digital service manual can save you time and money on common DIY maintenance tasks.
• Outboard Engine Troubleshooter – Not sure what’s wrong with your engine? Our free troubleshooting guide covers common issues across Mercury Outboards and more.

🔧 Browse More Mercury Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your engine shows serious issues, we strongly recommend visiting a certified marine mechanic. These guides are best suited for owners with basic to moderate mechanical experience.