VRO Fuel Pump – Fits Johnson/Evinrude 90-175 HP 2-Stroke 60° (Replaces 438400, 5004558)

$129.95

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Product Details

This VRO Fuel Pump is a direct-fit replacement for 90–175 HP Johnson and Evinrude 2-Stroke V4 and V6 60° outboard engines manufactured between 1991 and 2006. It ensures reliable fuel delivery, maintaining pressure above 3 PSI at all RPMs for consistent engine performance.

It serves as a direct replacement for Johnson/Evinrude part numbers 438400 and 5004558, as well as aftermarket equivalents including Sierra 18-8402, GLM 12480, and Mallory 9-35308.

Designed for a direct OEM replacement fit.
Requires premixed fuel and oil at a 50:1 ratio.
Features durable brass barb fittings for secure hose connections.

Part Number Matrix

Use this matrix to confirm equivalent references across OEM and aftermarket.

Brand	Part Number
Johnson/Evinrude	438400
Johnson/Evinrude	5004558
Sierra	18-8402
GLM	12480
Mallory	9-35308

Engine & Model Compatibility

Confirm your engine model/year in the table below.

For Johnson and Evinrude engines, this pump fits a wide range of V4 and V6 60° outboards from 1991 to 2006. Ensure you are using a 50:1 fuel/oil premix, as this pump bypasses the VRO oiling function.

Brand	Model	Rated HP	Stroke	Years	OEM Part No.	Notes
Johnson	60° V4 Outboard	90	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Johnson	60° V4 Outboard	115	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Johnson	60° V6 Outboard	150	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Johnson	60° V6 Outboard	175	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° V4 Outboard	90	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° V4 Outboard	115	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° V6 Outboard	150	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° V6 Outboard	175	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° Eagle Outboard	150	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio
Evinrude	60° Eagle Outboard	175	2-Stroke	1991–2006	438400/5004558	Must premix 50:1 oil/gas ratio

Technical Specs

Product Type: VRO Fuel Pump
Installation: Direct OEM replacement
Fuel Type: Gasoline (premixed with oil 50:1 ratio)
Connection: Pulse/Fuel In/Fuel Out ports
Housing Color: Black
Dimensions: 20 × 13.5 × 11 cm
Weight: 558g (1.23 lb)
Fitting Type: Brass barb fittings
Working Pressure: 3+ PSI at all RPMs
Warranty: 1-year against manufacturing defects
Other Technical Attributes: Requires premix fuel/oil at 50:1 ratio

What’s in the Box

1 x VRO Fuel Pump (438400/5004558)
1 x Mounting Hardware Set

Installation Notes

Disconnect the boat's battery and relieve any pressure from the fuel system.
Carefully note the position of the old lines, then disconnect the pulse line, fuel-in line, and fuel-out line.
Unbolt and remove the old VRO pump assembly.
Mount the new fuel pump securely with the provided hardware.
Connect the hoses to the appropriate ports on the new pump. The correct order from back to front is: Pulse, Fuel Out, Fuel In.
Ensure all fittings are tight to prevent fuel or vacuum leaks.
Prime the fuel system by squeezing the primer bulb until firm.
CRITICAL: This pump is intended for use with a premixed fuel/oil ratio of 50:1. The oil-mixing function of the original VRO system must be disabled.

Troubleshooting & FAQ

Which engines will this fuel pump fit?

This pump is designed for Johnson and Evinrude 90–175 HP 2-Stroke V4 and V6 60° outboard engines manufactured from 1991 through 2006. Always verify your part number against the cross-reference list to ensure a correct match.

This is a VRO pump, do I still need to premix my fuel and oil?

Yes. This unit replaces the original VRO pump assembly but functions only as a fuel pump. It does not perform oil mixing. You must use a premixed 50:1 fuel-to-oil ratio in your fuel tank. Failure to premix will lead to immediate and severe engine damage.

What are the signs of a failing fuel pump?

Common symptoms include the engine bogging down at high RPMs, difficulty starting, sputtering, intermittent power loss, or stalling. A fuel pressure test showing less than 3 PSI at idle or under load indicates a weak or failing pump.

How do I connect the three hose barbs?

The connection order is critical. Working from the back of the pump (closest to the mounting bracket) to the front, the order is: 1. Pulse line from the engine block, 2. Fuel Out line to the carburetors, 3. Fuel In line from the fuel tank.

Is this pump identical to the original Johnson/Evinrude VRO?

This is an aftermarket component that replaces the original assembly but serves only as a fuel pump. It bypasses the oil-mixing function (Variable Ratio Oiling) of the original VRO system. It is dimensionally and functionally equivalent for fuel delivery.

How often should a marine fuel pump be replaced?

There is no fixed replacement interval. However, it is advisable to replace the pump preventatively during a major engine service or if it is over 10-15 years old, especially if the engine has been exposed to ethanol-blended fuels which can degrade internal components over time.

OEM vs. Aftermarket?

This listing is an aftermarket replacement (not OEM). Built to OEM-level specifications with comparable materials. Manufactured in an ISO 9002 facility, batch-inspected for consistency.

Shipping speed & cost

We ship worldwide quickly—typical transit 5–15 days. Standard shipping is free; expedited options appear at checkout where available.

Warranty & returns

Covered by a 1-year warranty against manufacturing defects under normal use. If issues arise, contact support with your order details. Returns are accepted within our standard window (unused & in original condition). See our policy page or reach out for instructions.

Safety & Important Info

Verify images/specifications vs your original part. If anything differs—even if your model appears compatible—do not purchase.
This is an aftermarket replacement, not an OEM component.
Professional installation is recommended for safety and performance.

About Sea Sierra

Pro-Grade Standards — We supply marine parts engineered to OEM-level tolerances and tested for real-world conditions.
Fast Global Fulfillment — Free standard delivery to most regions in 5–15 days.
Manufacturer-Direct Value — Fair pricing without compromising on materials or QC.

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