Mallory Ignition 4060FI User Manual

FORM 1061 (REV. G) 01/12

INSTALLATION INSTRUCTIONS

COMP PUMP® SERIES 60FI

ELECTRIC FUEL PUMP

PART NO. 4060FI

NOTE: DO NOT RUN THIS PUMP WITHOUT FUEL (EXCEPT FOR BRIEF PERIODS WHILE PRIMING).

PARTS INCLUDED IN THIS KIT

4 Nuts, 5/16” – 24
4 Washers, Steel 5/16” Flat
4 Bolts, Steel 5/16”
1 Ring Terminal
1 Fuse, 7.5 AMP
1 Fuse Holder

GENERAL INFORMATION

The COMP PUMP® 60FI Series Electric Fuel Pump
is a high pressure fuel pump designed for fuel
injection applications. This fuel pump must be used with
return style (bypass) fuel pressure regulators.
Using this fuel pump with any other kind of fuel
pressure regulator (or no regulator) will result in
severe fuel pump damage, and will void the product
warranty.

At the bottom of the fuel pump is an air bleed system
designed to help in priming the fuel pump. The air
bleed line is plumbed to the fuel return line. If the fuel
pressures you are running are 10 PSI or less, put a
1/8 NPT plug in the air bleed port.

Be sure to install a suitable fuel filter (maximum 100
micron filtration) between the fuel tank and the fuel
pump. This prevents debris from becoming wedged
in the fuel pump’s Gerotor and locking it.

An additional fuel filter (maximum 10 micron, such
as the Mallory 160 Series COMP FILTER® Part
No. 3160) must be placed between the fuel pump
and the injectors. This prevents debris from clogging
the injectors.

SPECIFICATIONS

Maximum recommended operating pressure:

55 psi continuous, 65 psi intermittent

Minimum oil pressure switch current rating: 7.5 amps
Fuel pump over current protection: 7.5 amp fuse
Fuel application: Gasoline

This product is covered under one or more of the
following U.S. patents: 5,007,806; 4,998,557;
5,111,793; 5,123,436; 5,186,147.

SERVICE PARTS

Brush Kit 3146A
Seal and Repair Kit 3165

MALLORY IGNITION www.mallory-ignition.com

1

MOUNTING PROCEDURE

Step 1

Mount the pump as close as possible to the fuel tank
(at or below the level of the fuel tank pickup) in a well
ventilated area with minimal exposure to road debris.
Avoid exposing the pump and fuel lines to moving
parts and hot surfaces, such as the exhaust system.

NOTE: Increasing distance between the pump and
tank will decrease pump efficiency.

Step 2

Using the pump mounting bracket as a template,
locate mounting holes on a solid member, such as the
vehicle chassis. Drill clearance holes for 5/16” bolts.
See Figure 1. NOTE: To ensure against a potential

fire hazard from pump flooding, mount the pump
in a vertical position with the motor on top.

Step 3

Connect 5/16” or larger fuel lines as shown in Figure 2.
The 1/8” NPT outlet on the bottom of the pump is for
an air bleed line to assist pump priming. This air bleed
line is not necessary if the regulated pressure of your
system is less than 10 psi. NOTE: Use a thread

sealant compound on the fitting threads. Don’t
use thread sealing tape because it could get into
the Gerotor and lock the pump.

Step 4

Your system must have a Return Style Fuel Pressure
Regulator. For maximum efficiency, mount the pressure
regulator as close as possible to the injection system.
See instructions packaged with the regulator. The
regulator may be mounted before or after the fuel
injection.

WIRING PROCEDURE

Wiring the pump to an oil pressure switch will provide
power only when the ignition switch is on and the
engine is running. This will prevent the pump from
running if your engine stalls. Use 14 gauge wire or
larger and be sure to disconnect the battery ground
cable before wiring the pump. Refer to Figure 3 when
connecting the pump to an oil pressure switch.

The pump may be wired directly to the ignition switch
“ON” terminal and grounded to the frame or battery.
Refer to Figure 4 when connecting the pump to the
ignition switch “ON” terminal.

MAINTENANCE—PUMP DISASSEMBLY

If your pump fails to produce adequate pressure or
volume, it may require cleaning. Follow the steps
below to disassemble and clean your Mallory Electric
Fuel Pump. Refer to Figure 5 while performing the
following steps.

Step 1

Remove the pump from the vehicle and clean pump
exterior. Place the pump on its side on a clean work
surface. Scribe or draw a line across the pump
housing, port plate and fuel chamber so that you
can reassemble the pump correctly.

Step 2

Remove the two fuel chamber screws from the bottom
of the pump. Remove the fuel chamber and port plate.
NOTE: Do not drop the Gerotor from the pump cavity.

Step 3

Separate the port plate from the fuel chamber.

NOTE: Do not drop the air bleed check ball and spring
from the fuel chamber. Inspect the flame arrestor screen

in the fuel chamber and clean it if necessary.

FIGURE 1

3/8” NPT

OUTLET

AIRBLEED

1/8” NPT

2

BLACK –

(TOP)

(BOTTOM)

+ RED

3/8” NPT

INLET

Step 4

Place your hand beneath the Gerotor and hold the
pump in an upright position. The gerotor should slide
out of the pump and into your hand. NOTE: Observe

the position of the Gerotor and be careful not to
reverse it when you reassemble the pump. Inspect

the gerotor housing and port plate for wear. If the
gerotor has worn through the plating, return the pump
to Mallory for repair.

Step 5

Inspect the O-ring and gasket. Replace them if
necessary. Reinstall the air bleed spring and check
ball in the fuel chamber. Place the gasket and port plate
on the fuel chamber. Install the fuel chamber assembly
on the pump housing. Torque the fuel chamber screws.

NOTE: DO NOT OPERATE THE PUMP WITHOUT FUEL.
(Except for brief periods while priming).

IMPORTANT: Turn fuel chamber screws by hand
until they contact the chamber. Then torque to
24 inch/pounds

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