Mallory Ignition 4110, 4150 User Manual
FORM #1022 (REV. F) 8/00
INSTALLATION INSTRUCTIONS
®
COMP PUMP® SERIES 110 AND 140
ELECTRIC FUEL PUMPS
PART NOS. 4110, 4110A, 4110M, 4140, 4140M, 4141, 4141A, 4142, 4142A, 4150 AND 4150A
NOTE: DO NOT RUN THIS PUMP WITHOUT FUEL (EXCEPT FOR BRIEF PERIODS WHILE PRIMING).
Parts Included in this kit:
1 Electric Fuel Pump 1 Ring Terminal
1 Bag, Fuel Pump Hardware 4 Washer, Steel 5/16" Flat
1 Fuse Holder 4 Nut, 5/16" Flat
4 Bolt, Steel 5/16" 1 Fuse, 7.5 AMP
A fuel pressure regulator is included with COMP PUMP® 140 Series Electric Fuel Pump Kit
Part Nos. 4140, 4140M, 4141, 4141A, 4142 and 4142A.
Read all instructions carefully before beginning installation.
GENERAL INFORMATION
The COMP PUMP® 110 Series Electric Fuel Pump is a high volume fuel pump
designed for high performance street and marine applications. The operating fuel
pressure is factory set at 7 PSI. Normally, a fuel pressure regulator is not necessary.
We recommend a 5/16" or larger fuel line with this fuel system.
The COMP PUMP
pump designed for high performance street, racing and marine applications. The
operating fuel pressure is factory set at 12 PSI. This pump must be used with a fuel
pressure regulator to prevent carburetor flooding. We recommend a 3/8" or larger fuel
line with this fuel system.
The COMP PUMP
Style Regulator. These fuel systems must have a fuel return line installed between
the fuel pressure regulators fuel return port and the fuel tank. We recommend a 3/8"
or larger fuel return line.
When installing the fuel pump fittings, use a thread sealant compound (you can find
this at a hardware store) on the fitting threads. Do not use Teflon tape. Teflon tape can
get into the Gerotor and lock the pump. Also, do not overtighten the fittings. This could
damage the fuel chamber.
Be sure to install a suitable fuel filter (minimum 40 micron filtration) between the fuel
tank and the fuel pump. The Mallory COMP FILTER
recommended. This prevents debris from becoming wedged in the fuel pumps
Gerotor and locking it.
®
140 Electric Fuel Pump is a high volume high pressure fuel
®
Series 140 Part Nos. 4142 and 4142A come with a 3 Port Return
®
Series Part No. 3140 is
SPECIFICATIONS
Operating pressure: COMP PUMP® 110 Series factory set at 7 PSI
Inlet/outlet thread sizes: 3/8" NPT
Oil pressure switch rating: 7.5 AMP
Over current protection: 7.5 AMP fuse
Gasoline fuel applications: Part Nos. 4110, 4110M, 4140, 4140M, 4141,
Alcohol/Methanol fuel applications: Part Nos. 4110A, 4141A, 4142A and 4150A
The COMP PUMP
Part No. 4140M have been tested to UL 1130 AND SAE J1171 specifications and
meet U.S. Coast Guard, American Boat and Yacht Council, Inc. and the Nation Fire
Protection Association for Motor Craft NFPA No. 302 requirements for marine usage.
®
Series 110 Part No. 4110M and the COMP PUMP® Series 140
COMP PUMP
4142 and 4150
®
140 Series factory set at 12 PSI
SERVICE PARTS:
Part No. 3146A Brush Kit
Part No. 3165 Seal/Repair Kit, Gasoline (may be used to convert alcohol/metha-
Part No. 3166 Seal/Repair Kit, Alcohol/Methanol (may be used to convert gaso-
nol fuel pumps to gasoline)
line fuel pumps to alcohol/methanol)
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
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 minimual 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 shassis. Drill 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 fuel lines as shown in Figure 2 (A, B, C, or D). If your fuel system requires
a fuel pressure regulator, proceed to the instructions with the fuel pressure regulator.
FIGURE 1
BLACK WIRE
()
3/8" NPT
OUTLET
BYPASS ADJUSTMENT
(BYPASS PLUG AND JAM
NUT)
TOP
RED WIRE
(+)
3/8" NPT
INLET
BOTTOM
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, 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 acrosss 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. Inspect the flame arrestor screen in the
fuel chamber and clean it if necessary.
Step 4
Place your hand beneath the Gerotor and hold the pump in an upright position. The
Gerotor should slide out of the pump housing and into your hand. NOTE: Observe the
position of the Gerotor and be careful not to reverse it when you reassemble
the pump.
Step 5
Release the jam nut on the bypass plug. Mark the bypass plug location and count the
number of turns required to remove it. Remove the bypass spring and plunger.
Inspect the plunger. The plunger surface should be clean and slide freely in the
chamber. Check the plunger pad and remove any debris embedded in its surface.
Reinstall the bypass spring and plunger. Clean the bypass plug. Apply thread sealant
compound to the bypass plug threads. Install the bypass plug. Tighten the jam nut.
Step 6
Clean the Gerotor and install it in the pump housing. Inspect the O-ring and gasket.
Replace them if necessary. Place the gasket and port plate on the fuel chamber. Install
the fuel chamber assembly on the pump housing. Torque the fuel chamber screws to
24 in/lbs.
FIGURE 2A
FUEL PUMP KIT PART NO. 4110 (OPTIONAL FUEL
PRESSURE REGULATOR), 4140 OR 4141 WITH FUEL
PRESSURE REGULATOR PART NO. 4207 OR 4209
FUEL
FILTER
CARB.
REGULATOR
2
FUEL
PUMP
FUEL
FILTER
FUEL
TANK
COMP® FILTER
PART NO.
3140
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