VRO Fuel Pump – Fits Johnson/Evinrude 90-175 HP 2-Stroke 60° (Replaces 438400, 5004558)
VRO Fuel Pump – Fits Johnson/Evinrude 90-175 HP 2-Stroke 60° (Replaces 438400, 5004558) is backordered and will ship as soon as it is back in stock.
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VRO Fuel Pump – Fits Johnson/Evinrude 90-175 HP 2-Stroke 60° (Repla...
VRO Fuel Pump – Fits Johnson/Evinrude 90-175 HP 2-Stroke 60° (Replaces 438400, 5004558) is backordered and will ship as soon as it is back in stock.
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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