How to Disconnect the VRO on a Fuel Pump on a 1988 Johnson 60

When you disconnect the VRO -- the variable ratio oil system -- from the fuel pump of the 1988 Johnson 60-horsepower two-stroke outboard, you eventually have to reinstall it. The reinstallation process includes a test of the oil pickup line's ability to deliver oil and verifying the height of the oil pickup assembly in the outboard's oil tank.

Things You'll Need

  • Utility knife
  • T8 Torx screwdriver
  • Torque driver
  • T8 Torx bit
  • Plastic ties
  • T25 Torx screwdriver
  • Compressor
  • Screw
  • Hand-held vacuum pump
  • Replacement hose
  • Machinist's rule
  • 5/16-inch box-end wrench
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Instructions

  1. Removal

    • 1

      Cut the plastic tie holding the fuel outlet line at the top of the pump assembly with a utility knife. Push the line off the pump.

    • 2

      Compress the spring clamp holding the pulse line to the bottom-front of the pump assembly. Push the clamp back over the pulse line. Push the line from the pump assembly. Push the spring clamp holding the oil inlet line to the bottom-rear of the pump. Push the oil inlet line from its nipple.

    • 3

      Remove the pump’s connector from its retainer in the wire loom. Unplug the connector from the wiring harness. Remove the three T8 Torx screws on the back of the bracket that holds the pump-manifold bracket. Lift the pump from the bracket.

    Installation

    • 4

      Position the pump on the pump-manifold bracket and thread the retaining screws into place. Tighten the screws to 21 inch-pounds with a torque driver and T8 Torx bit.

    • 5

      Plug the pump wiring connector to the wiring harness. Snap the connector into the wire loom. Push the fuel outlet line onto its nipple at the top of the pump. Secure the hose with a plastic tie. Push the pulse line onto its nipple and slide the spring clamp over the nipple.

    • 6

      Loosen the T25 Torx retaining screws holding the oil pickup assembly in the tank. Remove the oil pickup assembly from the tank. Remove the pickup filter from the pickup assembly. Flush the filter with fresh fuel. Return the filter to the pickup assembly without moving the assembly supports.

    • 7

      Push the oil hose from the pickup assembly. Purge the hose of oil, using low-pressure compressed air. Plug one end of the hose with a screw. Apply a vacuum to the hose – 7 inches Hg -- with a hand-held vacuum pump. Maintain the vacuum for five minutes. Check the plug to ensure it’s holding; otherwise, replace the hose.

    • 8

      Connect the oil inlet line onto the oil pickup assembly and the nipple at the bottom-rear of the pump. Return the oil pickup assembly to the tank. Thread the Torx retaining screws into the bores on the oil pickup assembly.

    • 9

      Measure the distance from the bottom of the pickup flange to the end of the pickup tube with a machinist's rule. Slide it on the support rods until the distance between the bottom of the pickup flange and the end of the pickup tube is 6.9 inches for 1.8 gallon oil tanks or 8.8 inches for 3.0 gallon tanks. Tighten the retaining screws snugly.