VRO Fuel Pump Assembly – Fits Johnson/Evinrude 120-300hp V4/V6/V8 (Replaces 5004558, 438400)

VRO Fuel Pump Assembly – Fits Johnson/Evinrude 120-300hp V4/V6/V8

This VRO fuel pump assembly is designed for specific Johnson and Evinrude 2-stroke outboard engines, serving as a conversion to bypass the original oil mixing system. It is engineered for 120-300hp V4, V6, and V8 models, including 90° Looper and Crossflow engines from the 1990s to the early 2000s.

This unit is a direct replacement for multiple part numbers, including the current supersession 5007420. Note that installation requires using a pre-mixed fuel/oil ratio of 50:1, as the VRO (Variable Ratio Oiling) system will no longer be functional.

• Conversion Pump: Designed to bypass the VRO oil injection system. Your engine must run on a 50:1 premix fuel.
• Installation Profile: Features an external, bracket-mounted design consistent with OEM setups for a secure fit.
• Complete Assembly: Includes the main fuel pump unit for a straightforward replacement.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Johnson/Evinrude owners, here’s a guide to help you identify your engine’s serial/model: Johnson/Evinrude Serial Number Guide.

Technical Specifications

Package Contents

• 1 x VRO Fuel Pump Assembly (5004558)

Installation Guide

1. Safety First: Disconnect the battery terminals and work in a well-ventilated area away from any sparks or open flames.
2. Relieve Fuel Pressure: Follow your engine's service manual to safely relieve any pressure in the fuel lines.
3. Disconnect Old Pump: Carefully label and disconnect the fuel lines and electrical connectors attached to the old VRO pump.
4. Remove Old Unit: Unbolt and remove the original VRO pump from its mounting bracket.
5. Cap Oil Inlet: This is a critical step. This replacement pump bypasses oil injection. You must securely cap the oil inlet barb on the new pump to prevent air leaks.
6. Prepare Fuel System: From this point forward, your engine must run on a 50:1 fuel-to-oil premix in the main fuel tank.
7. Mount New Pump: Install the new fuel pump assembly onto the bracket. Note that some V6 applications may require slight bracket modification for a perfect fit.
8. Connect Fuel Lines: Reconnect the primary fuel inlet and the outlet line to the carburetors. The original pulse line from the crankcase should also be connected.
9. Final Checks: Reconnect the battery. Prime the fuel system using the primer bulb until firm and thoroughly check all connections for leaks before starting the engine.

Troubleshooting & FAQ

How do I confirm this pump fits my engine?
First, cross-reference your existing pump's part number with the numbers listed in our table, including 5004558, 438400, and the current supersession 5007420. Second, check the compatible engine models table. This pump fits most 90° V4 and some V6 models, but be aware that bracket modification is sometimes necessary for V6 applications.

Does this pump work with my VRO oil injection system?
No. This is a conversion fuel pump assembly designed to eliminate the VRO system, which is a common failure point. You must permanently switch to using a 50:1 premixed fuel/oil mixture in your tank. The oil inlet on the pump must be capped during installation.

What are the signs my original VRO pump is failing?
Common symptoms include the engine failing to start, bogging down under acceleration, stalling at idle, or surging. You might also hear an inconsistent pumping sound or see visible fuel leaks from the pump body, which are signs that immediate replacement is needed to prevent engine damage.

OEM vs. Aftermarket?
This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

How fast do you ship and how much does it cost?
We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

What is your warranty and return policy?
This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.