5001594 Water Pump Repair Kit for Johnson/Evinrude | JLM Marine

Water Pump Repair Kit for Johnson/Evinrude 120-140 HP Outboards (1985-1993)

This comprehensive water pump repair kit is engineered for Johnson/Evinrude outboard engines ranging from 120 HP to 140 HP, covering model years 1985 through 1993 (including S Suffix models). Designed to restore optimal cooling system performance, this kit provides all essential components for a complete water pump overhaul and routine maintenance.

This kit directly replaces OEM part number 5001594, ensuring proper fitment and reliable operation. It includes the water pump repair kit, thermostats, fuel filter, drain screw gaskets, and a gear oil pump—everything needed for comprehensive lower unit service.

• Complete water pump service solution with thermostat and fuel filter replacements
• Includes gear oil pump for full lower unit maintenance capability
• Fits both 120 HP and 140 HP Johnson/Evinrude 2-stroke outboards

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 kit includes the following components:

• 435929 5001595 – Water Pump Repair Kit × 1
• 434137 – Thermostat × 2
• 398319 – Fuel Filter × 1 View Part →
• 311598 – Drain Screw Gasket × 2
• 24OP149 – Gear Oil Pump × 1

Installation Guide

1. Preparation: Disconnect the fuel line and remove the propeller. Tilt the engine fully upward and drain the lower unit gear oil completely using the drain screw.
2. Remove Lower Unit: Disconnect the shift linkage and remove all mounting bolts securing the lower unit to the midsection. Carefully separate the lower unit from the engine.
3. Access Water Pump: Remove the water pump housing bolts and carefully lift off the housing. Note the orientation of all components for reassembly.
4. Remove Old Components: Extract the old impeller, wear plate, and gaskets. Inspect the pump housing and driveshaft for scoring or corrosion.
5. Install New Water Pump Kit: Apply marine grease to the new impeller vanes and insert it onto the driveshaft with vanes oriented correctly. Install the new wear plate and gaskets from kit 5001595.
6. Replace Thermostats: Remove the thermostat cover and replace both old thermostats with the new 434137 thermostats included. Ensure proper seating and gasket placement.
7. Install Fuel Filter: Locate the inline fuel filter connection and replace the old filter with the new 398319 fuel filter. Secure all clamps tightly.
8. Reassemble Water Pump Housing: Reinstall the water pump housing, ensuring all bolts are torqued to manufacturer specifications. Double-check gasket alignment to prevent leaks.
9. Reinstall Lower Unit: Reconnect the shift linkage and carefully align the lower unit with the midsection. Install and torque all mounting bolts evenly.
10. Refill Gear Oil: Using the included 24OP149 gear oil pump and new 311598 drain screw gaskets, refill the lower unit with fresh gear oil until it flows from the vent hole. Install both drain plugs with new gaskets.
11. Final Checks: Reinstall the propeller and reconnect the fuel line. Start the engine in a test tank or on muffs and verify strong water flow from the telltale indicator.
12. Test Run: Run the engine at idle for 5-10 minutes, checking for leaks around the water pump housing and lower unit seals. Monitor engine temperature to confirm proper cooling.

Troubleshooting & FAQ

Q: How do I know if my water pump needs replacement?
A: Common signs include weak or no water flow from the telltale indicator, engine overheating, steam from the powerhead, or loss of power. If your impeller is cracked, missing vanes, or hardened, immediate replacement is necessary.

Q: How often should I replace the water pump kit?
A: Most manufacturers recommend replacing the water pump impeller every 2-3 years or 200-300 hours of operation, whichever comes first. If you operate in sandy or silty water, more frequent replacement may be needed.

Q: Why are two thermostats included in this kit?
A: Johnson/Evinrude V4 and V6 outboards in this horsepower range use dual thermostats to regulate cooling system temperature evenly across both cylinder banks, ensuring optimal engine performance and longevity.

Q: Can I reuse the old gaskets and seals?
A: No, always replace all gaskets and seals during water pump service. Reusing old gaskets can lead to leaks, air intrusion into the cooling system, and potential engine damage from overheating.

Q: What's the difference between OEM and aftermarket water pump kits?
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.