438592 Water Pump Repair Kit for Johnson/Evinrude 40HP 48HP 50HP | JLM Marine

Water Pump Repair Kit – Fits Johnson/Evinrude 40HP, 48HP, 50HP (1989-1994)

This water pump repair kit is engineered for Johnson/Evinrude outboard engines rated at 40HP, 48HP, and 50HP manufactured between 1989 and 1994. Designed to restore reliable cooling system performance, this kit ensures your engine maintains optimal operating temperatures during operation.

This kit directly replaces OEM part number 438592, providing a cost-effective solution for routine maintenance or emergency repairs. It includes essential components to rebuild your water pump and keep your outboard running smoothly.

• Complete repair kit with all necessary components for water pump rebuild
• Includes bonus fuel filters, drain screw gaskets, and gear oil pump for comprehensive maintenance
• Direct fit for Johnson/Evinrude 40-50HP engines from 1989-1994 model years

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

This comprehensive maintenance package includes the following components:

• 438592 Water Pump Repair Kit x1
• 0398319 Fuel Filter x1 View Part →
• 3852224 Fuel Filter x1 View Part →
• 311598 Drain Screw Gasket x2
• 24OP149 Gear Oil Pump x1

Installation Guide

1. Disconnect the fuel line and remove the lower unit from the outboard motor according to your service manual.
2. Remove the water pump housing by unscrewing the retaining bolts. Note the orientation of all components for reassembly.
3. Extract the old impeller, gaskets, and seals from the water pump housing. Inspect the housing for wear or damage.
4. Clean all mating surfaces thoroughly using a gasket scraper and solvent to ensure proper sealing.
5. Install the new gasket from the repair kit onto the base plate, ensuring proper alignment with mounting holes.
6. Lubricate the new impeller with glycerin or soapy water (never use petroleum-based products). Bend the impeller blades in the direction of rotation as you insert it into the housing.
7. Install the impeller key or pin to secure the impeller to the driveshaft, ensuring it seats correctly.
8. Position the faceplate and upper gasket over the impeller, aligning all bolt holes carefully.
9. Reinstall the water pump housing onto the lower unit, torquing bolts to manufacturer specifications in a cross-pattern.
10. Replace the drain screw gaskets (included in package) on the lower unit drain and fill plugs before reinstalling.
11. Install the included fuel filters in the fuel line system according to your engine's fuel system layout.
12. Reattach the lower unit to the outboard, test the cooling system by running the engine with a flushing attachment, and verify strong water stream from the telltale port.

Troubleshooting & FAQ

Q: How do I confirm this water pump kit fits my Johnson/Evinrude engine?
A: Cross-reference your engine's HP rating and manufacturing year with the compatibility table above. This kit fits 40HP, 48HP, and 50HP models from 1989-1994. You can also verify using the Johnson/Evinrude serial number guide linked in the Compatible Engine Models section.

Q: How often should I replace my water pump impeller?
A: Most manufacturers recommend replacing the water pump impeller every 2-3 years or 200-300 hours of operation, whichever comes first. If you notice overheating, reduced water flow from the telltale, or operate in sandy/debris-filled water, inspect and replace more frequently.

Q: What are the signs that my water pump is failing?
A: Common symptoms include weak or no water flow from the telltale (pee hole), engine overheating alarms, steam from the engine, reduced performance, or visible damage to the impeller blades during inspection. Replace immediately if any of these occur.

Q: Can I use the included fuel filters and gear oil pump with my engine?
A: Yes, this package includes bonus maintenance items. The fuel filters (0398319 and 3852224) are compatible with Johnson/Evinrude fuel systems from this era. The gear oil pump (24OP149) simplifies lower unit oil changes. Verify part numbers against your service manual if unsure.

Q: What's the difference between this aftermarket kit and the OEM part?
A: 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.

Q: How fast do you ship and how much does it cost?
A: 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.

Q: What is your warranty and return policy?
A: 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.