Aftermarket VRO-Style Fuel Pump for Johnson/Evinrude 90–175 HP 2-Stroke 60° Outboards – Replaces 438400 and 5004558
Aftermarket VRO-Style Fuel Pump for Johnson/Evinrude 90–175 HP 2-Stroke 60° Outboards – Replaces 438400 and 5004558 is backordered and will ship as soon as it is back in stock.
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Aftermarket VRO-Style Fuel Pump for Johnson/Evinrude 90–175 HP 2-St...
Aftermarket VRO-Style Fuel Pump for Johnson/Evinrude 90–175 HP 2-Stroke 60° Outboards – Replaces 438400 and 5004558 is backordered and will ship as soon as it is back in stock.
Product Details
This aftermarket VRO-style fuel pump is listed as a replacement for selected 90–175 HP Johnson and Evinrude 2-stroke V4 and V6 60° outboard applications. It is intended to provide fuel delivery through the pulse, fuel-in and fuel-out connections used by the original pump arrangement.
This fuel-only replacement does not provide the oil-mixing function of the original Variable Ratio Oiling system. When used in an application that originally relied on VRO oiling, the oiling system must be properly disabled and the engine must be operated with the manufacturer-recommended premixed fuel and oil.
Reference numbers associated with this replacement include Johnson/Evinrude 438400 and 5004558, Sierra 18-8402, GLM 12480 and Mallory 9-35308. Confirm the number, hose-port arrangement and pump appearance against the original component before ordering.
- Aftermarket replacement for selected Johnson and Evinrude 2-stroke outboards.
- Fuel-pump function only; it does not perform VRO oil mixing.
- Three-port arrangement for pulse, fuel-in and fuel-out connections.
- Brass barb fittings for hose connections.
Part Number Matrix
The following numbers are reference and cross-reference numbers associated with this replacement. They should be checked against the original pump and engine application before installation.
| Brand | Part Number |
|---|---|
| Johnson/Evinrude | 438400 |
| Johnson/Evinrude | 5004558 |
| Sierra | 18-8402 |
| GLM | 12480 |
| Mallory | 9-35308 |
Engine & Model Compatibility
The supplied application information covers Johnson and Evinrude 90–175 HP 2-stroke 60° outboards, including V4, V6 and certain 60° Eagle applications, generally identified as 1991–2006. Application coverage can vary by exact model, serial number and fuel-system configuration. Verify the engine label, original pump number and port layout before purchase.
| Brand | Model | Rated HP | Stroke | Years Listed | Reference Part No. | Important Note |
|---|---|---|---|---|---|---|
| Johnson | 60° V4 Outboard | 90 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Johnson | 60° V4 Outboard | 115 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Johnson | 60° V6 Outboard | 150 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Johnson | 60° V6 Outboard | 175 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° V4 Outboard | 90 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° V4 Outboard | 115 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° V6 Outboard | 150 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° V6 Outboard | 175 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° Eagle Outboard | 150 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
| Evinrude | 60° Eagle Outboard | 175 | 2-Stroke | 1991–2006 | 438400 / 5004558 | Confirm exact model and serial conditions. |
Technical Specs
- Product Type
- Aftermarket VRO-style fuel pump
- Function
- Fuel delivery only; does not perform oil mixing
- Installation
- Replacement installation for a matching original pump arrangement
- Fuel Type
- Gasoline premixed with oil when required by the converted fuel system
- Connection
- Pulse, fuel-in and fuel-out ports
- Housing Color
- Black
- Dimensions
- 20 × 13.5 × 11 cm
- Weight
- 558 g (1.23 lb)
- Fitting Type
- Brass barb fittings
- Working Pressure
- Listed at 3+ PSI
- Warranty
- 1 year against manufacturing defects, subject to the applicable warranty terms
What’s in the Box
- 1 × aftermarket VRO-style fuel pump
- 1 × mounting hardware set
Installation Notes
- Disconnect the boat battery and relieve pressure from the fuel system before beginning work.
- Record the existing hose positions, then disconnect the pulse, fuel-in and fuel-out lines.
- Remove the original pump assembly and inspect the hoses, fittings and mounting surface.
- Mount the replacement pump securely using the supplied hardware where applicable.
- Connect the hoses to the matching ports. The listed back-to-front order is: Pulse, Fuel Out, Fuel In.
- Secure all connections and check carefully for fuel or vacuum leaks.
- Prime the fuel system by squeezing the primer bulb until firm.
- Critical: This replacement is a fuel pump only. The original VRO oil-mixing function must be disabled, and the engine must receive the correct premixed fuel/oil ratio before operation.
Troubleshooting & FAQ
Which engines is this fuel pump intended for?
The supplied application information identifies selected Johnson and Evinrude 90–175 HP 2-stroke V4, V6 and 60° Eagle outboards generally listed from 1991 through 2006. Always compare the original part number, engine model, serial information and port arrangement before installation.
Do I need to premix fuel and oil?
Yes, when this fuel-only replacement is used in place of an oil-mixing VRO assembly. The unit does not meter or mix oil. Follow the engine manufacturer’s required fuel/oil ratio; the supplied listing specifies a 50:1 premix.
What are common signs of a failing fuel pump?
Possible symptoms include difficult starting, bogging at higher RPM, sputtering, intermittent power loss or stalling. Inspect the complete fuel system and test fuel delivery using the appropriate service procedure before replacing parts.
How are the three hose connections arranged?
The listed order from the back of the pump toward the front is: 1. pulse line from the engine, 2. fuel-out line to the engine fuel system, and 3. fuel-in line from the tank. Confirm the markings and original hose routing on your specific pump.
Is this an original Johnson/Evinrude VRO pump?
No. This listing is for an aftermarket replacement. It is intended to replace the fuel-pump function of a matching original assembly and does not reproduce the original VRO oil-mixing function.
How often should the pump be replaced?
There is no universal replacement interval. Inspect the pump during routine engine service and replace it when fuel delivery, starting or operating symptoms indicate a problem, or when deterioration is visible.
What should I verify before ordering?
Verify the engine brand, horsepower, stroke, model, year or serial range, original pump number, mounting pattern and hose-port arrangement. Do not rely on horsepower alone to establish fitment.
Warranty and returns
The listed warranty is 1 year against manufacturing defects under applicable terms. Contact support with order details if a problem occurs. Returns should follow the seller’s current return policy and condition requirements.
Safety & Important Information
- Work in a well-ventilated area away from sparks, flames and other ignition sources.
- Verify the replacement against the original pump before installation.
- Do not operate the engine without the required fuel/oil mixture after the VRO oiling function has been bypassed.
- Inspect every connection for leaks before starting the engine.
- Professional marine service is recommended when fuel-system or oiling-system modifications are required.
- This is an aftermarket replacement, not an OEM component.
About Sea Sierra
- Pro-Grade Standards — Marine replacement parts selected for dependable service in demanding operating conditions.
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