Aftermarket VRO Conversion Fuel Pump for Johnson/Evinrude 60° 2-Stroke Outboards, 90–175 HP – Replaces 438400, 5004558
Aftermarket VRO Conversion Fuel Pump for Johnson/Evinrude 60° 2-Stroke Outboards, 90–175 HP – Replaces 438400, 5004558 is backordered and will ship as soon as it is back in stock.
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Aftermarket VRO Conversion Fuel Pump for Johnson/Evinrude 60° 2-Str...
Aftermarket VRO Conversion Fuel Pump for Johnson/Evinrude 60° 2-Stroke Outboards, 90–175 HP – Replaces 438400, 5004558 is backordered and will ship as soon as it is back in stock.
Product Details
This aftermarket VRO conversion fuel pump is designed for select Johnson and Evinrude 60-degree V4 and V6 two-stroke outboard motors in the 90–175 HP range. It is intended for engines where the VRO oil-injection system has been disconnected or disabled and premixed fuel is required.
The pump is listed as a replacement for Johnson/Evinrude OEM part numbers 438400 and 5004558. Confirm the original pump, engine model, year, and connection layout before ordering, because fitment can vary within the same horsepower range.
- Aftermarket replacement VRO conversion fuel pump assembly.
- Designed for selected Johnson/Evinrude 60-degree two-stroke outboards.
- For applications using premixed gasoline and oil after VRO oil injection has been disconnected.
- Direct-replacement design for the listed applications; verify all connections before installation.
Part Number Matrix
Use these references to compare the replacement pump with the part being removed.
| Brand | Manufacturer Part Number |
|---|---|
| Johnson/Evinrude | 438400 |
| Johnson/Evinrude | 5004558 |
Engine & Model Compatibility
The following range describes the intended application. Always compare the engine model and the original pump before purchase; a horsepower or year match alone does not confirm fitment.
| Brand | Model / Configuration | Rated HP | Stroke | Model Years | Replacement Reference | Application Note |
|---|---|---|---|---|---|---|
| Johnson | 60° V4/V6 outboard | 90 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Johnson | 60° V4/V6 outboard | 115 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Johnson | 60° V4/V6 outboard | 150 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Johnson | 60° V4/V6 outboard | 175 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Evinrude | 60° V4/V6 outboard | 90 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Evinrude | 60° V4/V6 outboard | 115 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Evinrude | 60° V4/V6 outboard | 150 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
| Evinrude | 60° V4/V6 outboard | 175 | 2-Stroke | 1991–2006 | 438400 / 5004558 | For engines with VRO oil injection disconnected; use premixed fuel. |
Technical Specifications
- Product Type
- VRO conversion fuel pump assembly
- Application
- Selected Johnson/Evinrude 60° V4 and V6 two-stroke outboards
- Installation
- Replacement installation; compare the original pump and connections before fitting
- Fuel Type
- Gasoline premixed with two-stroke oil
- Recommended Premix
- 50:1 fuel-to-oil ratio where specified by the engine conversion setup
- Housing Material
- Polymer composite
- Housing Color
- Black
- Dimensions
- 20 × 13.5 × 11 cm
- Weight
- 558 g (1.23 lb)
What's in the Box
- 1 × VRO conversion fuel pump assembly
Installation Notes
- Turn the engine off, disconnect the battery, and relieve fuel-system pressure before beginning work.
- Work in a well-ventilated area away from flames, sparks, and other ignition sources. Place absorbent towels around the pump to catch spilled fuel.
- Label and carefully disconnect the fuel inlet, fuel outlet, pulse-limiter, and other connected hoses as applicable to the engine.
- Disconnect any electrical connectors attached to the existing pump.
- Remove the mounting fasteners and take out the old pump assembly.
- Install the replacement pump in the same orientation and secure it with the original mounting hardware or suitable hardware for the application.
- Reconnect each hose and electrical connector to the correct port. Inspect hoses and clamps for damage or looseness.
- Confirm that all connections are tight and that the fuel lines are routed away from heat and moving parts.
- Prime the fuel system according to the engine service manual and use the correct premixed fuel for the VRO-disconnected configuration.
- Start the engine in a safe test area and inspect carefully for fuel, air, or oil leaks before operating the boat.
Troubleshooting & FAQ
What engines is this pump intended to fit?
It is intended for selected Johnson and Evinrude 60-degree V4 and V6 two-stroke outboards in the 90–175 HP range, with listed model years from 1991 through 2006. Confirm the exact engine model, year, original pump, and hose connections before ordering.
Which part numbers does it replace?
This replacement is listed for Johnson/Evinrude OEM part numbers 438400 and 5004558. Part-number matching should be combined with a comparison of the original pump and engine configuration.
Is this a direct-fit replacement?
It is designed as a replacement pump for the listed applications, but fitment should be verified using the original pump, mounting arrangement, hose routing, and engine model information. Do not rely on horsepower alone.
Can the original oil-injection system be used with this pump?
No. This is a VRO conversion fuel pump intended for engines where the VRO oil-injection system has been disconnected or disabled. Follow the engine manufacturer's conversion requirements and use the specified premixed fuel and oil ratio.
What fuel mixture should be used?
The listed application uses premixed gasoline and two-stroke oil at a 50:1 ratio. Confirm the required ratio for your specific engine and conversion procedure in the service documentation before operation.
What are common symptoms of a failing fuel pump?
Possible symptoms include hard starting, sputtering, bogging at higher speeds, intermittent stalling, rough idling, and reduced engine power. Fuel restrictions, damaged hoses, air leaks, or ignition problems can cause similar symptoms, so diagnose the complete fuel system.
How should the existing pump be tested?
A qualified marine technician can inspect the pump and perform the applicable fuel-pressure and fuel-flow tests using the specifications for the engine. Check for cracked housings, damaged hoses, loose fittings, and fuel leaks.
Is this an OEM part?
No. This is an aftermarket replacement component intended to replace the listed Johnson/Evinrude pump references. Compare the original component and application details before installation.
How quickly is the product shipped?
Shipping availability and delivery estimates depend on the destination and the service selected at checkout.
What is the warranty and return policy?
Warranty coverage and return eligibility are governed by the applicable order and store policies. Contact customer support before returning a product and retain the order information and original packaging.
Safety & Important Information
- Verify the original pump, OEM reference number, engine model, year, stroke, horsepower, and hose connections before purchasing.
- Do not operate an engine with leaking fuel lines, loose fittings, damaged hoses, or an improperly configured fuel system.
- This is an aftermarket replacement component, not an original equipment manufacturer part.
- Follow the engine service manual and applicable marine safety requirements. Professional installation by a qualified marine mechanic is recommended.
- Use only the fuel and oil mixture specified for the VRO-disconnected configuration.
About Sea Sierra
- Marine Replacement Parts — We supply replacement components for a range of marine repair applications.
- Global Fulfillment — Shipping options and delivery times vary by destination and are shown during checkout.
- Application-Focused Support — Compare your original component and engine details before ordering, and contact support if you need help checking an application.
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