Mercury 40 HP 4-Stroke EFI Outboard 2016–2020 Service Repair Manual – PDF Download

🛠️ Mercury 40 HP 4-Stroke EFI Outboard 2016–2020 Service Repair Manual – PDF Download

🧰 OEM Factory Workshop Manual – Covers Mercury 40 HP EFI 4-Stroke Outboard Engines (Serial No. 1C453840 and up)
📲 Instant PDF Download – Fully compatible with Windows, macOS, iOS, Android, and Linux
🔧 Used by certified Mercury technicians and marine service professionals worldwide

🔍 Model Background

The Mercury 40 HP Four Stroke EFI outboard (2016–2020) was part of Mercury’s in-house designed mid-range 4-stroke platform, offering exceptional fuel economy, quiet performance, and reliability in a lightweight, compact package. Built on a 995cc inline-3 four-stroke engine, this model was engineered for versatility across a wide range of small boats, from aluminum fishing rigs to inflatables and pontoons.

Equipped with Electronic Fuel Injection (EFI), the 40 HP Four Stroke delivered quick cold starts, smooth throttle response, and improved fuel efficiency over earlier carbureted models. It featured a single overhead camshaft (SOHC), mechanical throttle and shift controls, and was compatible with Mercury’s SmartCraft system in certain configurations.

Thanks to features like a maintenance-free valve train, top-mounted oil filter, and color-coded service points, the 40 HP EFI was easy to maintain and dependable in both freshwater and saltwater environments. Between 2016 and 2020, it became a top choice for boaters looking for low noise, low emissions, and long-term reliability in the 40 HP class.

📆 Model Years Covered:

• Mercury 40 HP EFI – 2016
• Mercury 40 HP EFI – 2017
• Mercury 40 HP EFI – 2018
• Mercury 40 HP EFI – 2019
• Mercury 40 HP EFI – 2020

📘 Manual Details:

• Model: 40 HP EFI Four Stroke (Bigfoot & Standard)
• Serial Numbers: 1C453840 and above
• Document Type: OEM Service & Repair Manual (Factory Shop Manual)
• Language: English
• Publisher: Mercury Marine
• Pages: 500+ with detailed repair procedures and color schematics

📚 Manual Sections Include:

• General Information & Specifications
• Ignition & Charging System
• Ignition coil, ECM, charge coil, timing test procedures
• Fuel System
• Electronic Fuel Injection (EFI), fuel pump, fuel rail, injectors, link & sync
• Powerhead
• Valve clearance, cylinder head, camshaft, pistons, crankcase
• Cooling System
• Thermostat, water pump, passages, overheat diagnostics
• Midsection & Exhaust
• Exhaust housing, mount brackets, anti-ventilation plate
• Gearcase Assembly
• Propshaft, gear set, seals, water pickup, shift rod adjustment
• Control Linkage & Adjustment
• Throttle and shift linkage, idle speed tuning
• Wiring Diagrams
• Complete color-coded electrical schematics and component locations

💾 Format & Compatibility:

• File Format: PDF
• Searchable & Bookmarked: ✅ Yes
• Printable: ✅ Yes – Entire manual or specific sections
• Compatible With: Windows, macOS, iOS, Android, Linux
• Delivery: 📩 Instant Digital Download

🔍 Keywords:

Mercury 40 HP EFI outboard service manual PDF, 2016–2020 repair guide, FourStroke diagnostics, fuel injection, wiring diagrams, gearcase, powerhead, OEM PDF

❓ Mini FAQ:

Q: Is this the full official Mercury factory manual?
A: Yes – this is the complete OEM service manual used by authorized Mercury marine technicians.

Q: Does it include EFI diagnostics and full schematics?
A: Yes – EFI system repair and color-coded electrical diagrams are fully covered.

Q: Can I view this on my tablet or phone?
A: Absolutely – the PDF is fully optimized for all digital devices.

🧭 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.