Fuel pump replacement advice Evinrude 4006E

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    archangel

    Canada Member - 1 Year
    Replies: 118
    Topics: 21
    #179135

    I have a failed fuel pump on an 1970 Evinrude 4 hp, model 4006E, and understand that rebuilding is not an option and that a replacement is necessary. The recommended replacement is BRP part #0388684 and the only ones I have found available for purchase in my internet searches are USD$120-plus. Can anyone recommend an alternative that will allow me to make this repair for a more reasonable cost, one that reflects the actual value of this motor more closely? I have just completed a complete ignition, carb, and water pump rebuild on this motor, so I have already sunk quite a few bucks into it. Any advice would be greatly appreciated.

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    fleetwin

    US Member - 2 Years
    Replies: 2809
    Topics: 36
    #179138

    I think there is a OMC rebuild kit for these little pumps, don’t know the part number right now….But, these little things tend to “explode” when disassembled, pieces go everywhere, making it unlikely you will get it back together properly….So, be sure to mark all the casing pieces to be sure you line them up properly when reassembled, then take it apart inside a clean white bucket/deep tray so none of the bits and pieces will get away….Will look for the rebuild kit part number for you….
    Yes, a new pump is priced ridiculously, I would look for a reasonably priced (low) used one if rebuilding doesn’t pan out. But, beware, these little pumps come in many configurations, and not all will work on your engine….A used pump is surely a gamble, so be sure it is priced to reflect the gamble you are taking….Don

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    amuller

    US Member - 2 Years
    Replies: 892
    Topics: 141
    #179139

    There are various ways to approach this, including buying some bulk diaphragm material and making your own, and cobbling up a lawnmower pump–cost about $5-10.

    But I note there are clone pumps on Amazon for $16 and change. https://www.amazon.com/OMC-Johnson-Evinrude-BRP-Assembly/dp/B07D8Y74RW This might be the most painless way to go.

    OMC at one time did, I think, list parts for these small pumps, and someone can probably post a breakdown. My recollection is that they are somewhat fussy and fiddly to assemble, but far from impossible. If it really isn’t pumping, you likely have nothing to lose by taking it apart–being careful to retain little springs, etc. The diaphragm may be hard, or ripped. 1970 was before the days of alcohol-containing fuels and organic materials used then didn’t necessarily stand up well to ethanol content….

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    fleetwin

    US Member - 2 Years
    Replies: 2809
    Topics: 36
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    archangel

    Canada Member - 1 Year
    Replies: 118
    Topics: 21
    #179141

    Thanks for the quick replies. Though they may be mistaken, Marine Engine confirmed to me that original 4006E fuel pump does not have a rebuild kit available. It seems to me that I recall an ancient thread that confirms this and that the root of the issue was a bad fuel pump design that OMC regularly replaced rather than continue making kits to rebuild. No one would have any idea if the more commonly available pumps, like the one you’ve listed, are interchangeable with the 0388684 pump which is listed as the replacement part for the 4006E, would they?

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    fleetwin

    US Member - 2 Years
    Replies: 2809
    Topics: 36
    #179143

    Marinengine may in fact be giving you the correct advice. To be honest, I have never even tried to rebuild one of these pumps, don’t have the dexterity or eyesight to accomplish it successfully…. OMC never made repair kits “back in the day”, they just came about late in the 80s. I just “asssssumed” the kits would work on all the little pumps….Will look for a reasonable used one for you…I would stay away from most of the cheap fits all replacements….Don’t let the low price fool you, they probably won’t fit properly and won’t last too long….
    Here is another one of the OEM kits from ebay, doesn’t seem to mention anything about older pumps that can’t be rebuilt:
    https://www.ebay.com/itm/New-Johnson-Evinrude-OEM-Outboard-Fuel-Pump-Repair-Kit-393088-BRP-OMC/261757288199?epid=4027753950&hash=item3cf1f33f07:g:E~YAAOSwX6RcLS3d:sc:USPSFirstClass!02908!US!-1
    Someday, I will muster the courage to try this repair again…
    Will keep looking for a used pump…Don

    frankr
    frankr

    US Member - 1 Year
    Replies: 4576
    Topics: 43
    #179144

    Thanks for the quick replies. Though they may be mistaken, Marine Engine confirmed to me that original 4006E fuel pump does not have a rebuild kit available. It seems to me that I recall an ancient thread that confirms this and that the root of the issue was a bad fuel pump design that OMC regularly replaced rather than continue making kits to rebuild. No one would have any idea if the more commonly available pumps, like the one you’ve listed, are interchangeable with the 0388684 pump which is listed as the replacement part for the 4006E, would they?

    It is true that OMC did make a junk-design pump somewhere along that year. If that is what you have, parts are not available. On the other hand, they were so bad that it might have been replaced with the better design. The only way that I know to tell for sure what you have is take it apart. The crappy design had flaps on the diaphragm instead of “real” check valves.

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    fleetwin

    US Member - 2 Years
    Replies: 2809
    Topics: 36
    frankr
    frankr

    US Member - 1 Year
    Replies: 4576
    Topics: 43
    #179148

    I replaced several of the poor deign pumps while the motors were still in warranty. That’s why I’m thinking it is kind of unlikely you still have one of the un-rebuildable ones. But who knows????

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    amuller

    US Member - 2 Years
    Replies: 892
    Topics: 141
    #179151

    I have noticed on my few small OMC motors that some have the small square pump and some have the larger one with five screws. How interchangeable are these?

    The small West Bend/Chrysler/Force pumps use diaphragm flaps for valves, are very simple, and seem to have worked for many years with the same design…..?

    frankr
    frankr

    US Member - 1 Year
    Replies: 4576
    Topics: 43
    #179153

    I have noticed on my few small OMC motors that some have the small square pump and some have the larger one with five screws. How interchangeable are these?

    The small West Bend/Chrysler/Force pumps use diaphragm flaps for valves, are very simple, and seem to have worked for many years with the same design…..?

    True, some of those kind of pumps work ok. Chainsaws generally have flap valves but they only have to lift the fuel a couple of inches. OMC tried it twice that I know of, and both failed.

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    archangel

    Canada Member - 1 Year
    Replies: 118
    Topics: 21
    #179156

    #179151 Reply new
    I have noticed on my few small OMC motors that some have the small square pump and some have the larger one with five screws. How interchangeable are these?

    This is my question, too. I am curious to know if I can put the pump Don sent the link for or perhaps a pump from a similar era 6 hp on the 4006E. The difference in price between all the other pumps I am seeing available and the 0388684 pump is so massive. They all look like the same external layout and dimensions, are they that radically different internally?

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    fleetwin

    US Member - 2 Years
    Replies: 2809
    Topics: 36
    #179159

    Well, they are not radically different inside, but orientation of the fuel line outlet differs as does the orientation of the pump mounting screws, some are vertical, some horizontal. The other issue is that oftentimes you will see a tab on the fuel pump saying up with an arrow, this must be pointed upwards or the pump won’t work properly….
    The used pump I pointed out is the original part number for the 4hp 381815, which supercedes to the expensive new part number….
    At this point, my curiosity has peeked…I would probably take the risk of buying the OMC rebuild kit, then pulling your pump apart to see if it can be rebuilt….Or, better yet, pull it apart first and post pictures….Looks like the kit has new inner housings/springs/cups that might replace the original flapper diaphragm system….
    Again, please be very careful disassembling your pump….Get an indullable white marker to draw a line across all the plates/plastic housings, this will ensure all the pieces are properly oriented during reassembly. Be very careful pulling it apart, do it in a clean white bucket to keep bits/pieces from flying away….

    Tubs
    Tubs

    US Member - 1 Year
    Replies: 2491
    Topics: 148
    #179161

    I got into one of those pumps with the discs working on the
    same motor for a friend.
    Long story short I got another pump with valves in it but
    It wouldn’t work either because the orientation was wrong. Found
    the sight in the link I’m sending you in a PM, took the pump apart
    and reassembled it for the motor I was working on, and it’s still
    working 7 years later. I tried to post the link but again when
    trying to post a link here when you hit “submit” everything just
    disappears. “Poof”

    • This reply was modified 4 months, 3 weeks ago by TubsTubs.
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    archangel

    Canada Member - 1 Year
    Replies: 118
    Topics: 21
    #179162

    Thanks to all for the information and knowledge. It’ll be a couple of weeks before I get to it as it is at the cottage, but I will update you all with my findings. Thanks again.

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