Evinrude 5520 Powerhead Vs. Johnson

[Buccaneer]

I started working on the 5520 Evinrude 5.5 hp that was
a former home to a colony of mice. It was so "icky" I
sandblasted the powerhead, and found more corrosion
from the mice piss that was first noticeable.
There’s two little pinholes ate into the crankcase that
I could JB Weld. The Intake manifold is toast.
It looks like I could get a whole different powerhead
for about double of what just the intake manifold might
cost. I’m a little torn of which way to go, as it had
83 psi compression on both cylinders, which seems
pretty good?
Does anyone know right off which years have the same
powerhead and intake manifold where all the original
gizzmos will bolt right up?
All I can tell from the parts numbers that for the same
year Evinrude and Johnson crankcase halves have the
same parts numbers, but that’s not to say a different
year block will work, correct?
What would a guy need…… an interchange manual?

crankcase (* mine)

Evinrude

5520* 1960 0377948

5521 1960 0377948

5519 1959 0377794

5518 1959 0377794

5517 1958 0376514

5516 1958 0376514
==========================
Yonson

CD-17 1960 0377948

CD-16 1959 0377794

CD-15 1958 0376514

Thanks, Buccaneer

Prepare to be boarded!

[frankr]

Cylinder and crankcase are a matched pair and cannot be intermixed. My book sez part number 386491 cylinder and crankcase assembly fits the following:
Evinrude 5hp 1965-1970
Evinrude 5.5hp 1959-1964
Evinrude 6hp 1965-1970

Johnson CD-16 thru 25
Johnson LD 10 thru 13

[Buccaneer]

Thanks for the information Frank.
That being said, is your information suggesting
I could get a complete powerhead from any of
those models you listed, and it would bolt up
to my lower unit, and everything else would bolt
onto said powerhead, such as fuel pump, etc?
Also, is there a "work around" for replacing the
fuel pump on the 5520? The repair kit appears to
be NLA, and refers you to buy a new pump for $106.

Thanks!

Prepare to be boarded!

[ede]

I have several NOS cylinder blocks p/n 386491 Interested, send me a PM

[fleetwin]

OK, well the Evinrude 5520 is a 1960 5.5hp, that is what you have, correct? This model is a bit unique because it has the port for the fuel pump. I don’t know why later models have a different crankcase number, I would have thought they would fit. In any event, earlier model powerheads will definitely not fit your engine, including the 1959 models without the fuel pump.
You mention that the powerhead appears to be in good shape, just suffers from mouse corrosion. I don’t see any problem in sanding down the affected spots on the powerhead and applying marine tex/jbweld. Finding a decent 1960 intake manifold shouldn’t be difficult or expensive.

[Buccaneer]

Fleetwin, thanks for saving me from a "boo boo". I didn’t notice
that between 59 and 60 is when they switched over from the
pressurized fuel tank to having a fuel pump.
Regarding the fuel pump on the 1960, is it possible to substitute
a cheap impulse pump (instead of the $106 bolt on pump) by
attaching a hose barb in the block and using that as the impulse
port for the cheap fuel pump?
I’m game for using the old block, with a different intake manifold and carburetor,
if I can resolve the fuel pump issue for a lot cheaper than $106 🙁
Thanks, Buccaneer

Prepare to be boarded!

[fleetwin]

I’m sure you can find a used small OMC pump for much less money that will mount to bypass cover like it is supposed to. I’m not sure if the sierra direct replacements are more reasonably priced. I’m not sure if the fuel pump port hole is threaded, but you could surely install a nipple and install some other style pump if it is.
The carb is NG also? If so, only the 1959-60 carbs will work due the change in lower motor covers.
PS-Be careful if you choose to go the used OMC pump route, it must be oriented correctly or won’t work. Looks like the 60s-70s 6hp engines use the same replacement fuel pump, so a used on from a 6hp should work. Keep in mind that the little fuel pumps have a screen filter, so your engine’s externally mounted filter could be eliminated, although it can’t hurt to leave it there.

[Buccaneer]

Fleetwin, thanks again for the valuable information.
Sounds like the fuel pump shouldn’t be a road block then.
Good to know about the carbs, as I’ll need at least the
upper portion of a different one.

Prepare to be boarded!

[fleetwin]

I will keep my eyes open, try webvertise as well.

[Author]

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