Mallory Ignition 4309 User Manual
FORM 1078 (Rev B) 01/12
INSTALLATION INSTRUCTIONS
3-PORT COMPETITION
FUEL PRESSURE REGULATOR
(RETURN STYLE)
PART NO. 4309
NOTE: DO NOT RUN THIS PUMP WITHOUT FUEL (EXCEPT FOR BRIEF PERIODS WHILE PRIMING).
IMPORTANT: This regulator must use a fuel return line. The fuel return line runs between the fuel return port of the regulator and the fuel
tank. Fuel pressures cannot be adjusted if the fuel return line is absent.
PART INCLUDED IN THIS KIT
1 3-Port Fuel Pressure Regulator
1 Bracket
2 Bracket Mounting Screws
1 Bypass Spacer (to modify COMP PUMP® 110 and 140 Series
Electric Fuel Pumps)
SPECIFICATIONS:
Port thread sizes (ALL): 3/8” NPT
Adjustment range: 3-12 PSI (approximate)
Fuel Application: Gasoline, Automotive/Street and Racing
applications
GENERAL INFORMATION
Mallory’s 3-Port, return style regulator regulates fuel pressure between high pressure fuel pumps and carburetors. The
regulator is recommended for Mallory COMP PUMP® 110, and 140 Series Electric Fuel Pumps.
NOTE: This regulator is not recommended for pumps over 200 gallons per hour.
By returning excess fuel and fuel pressure to the fuel tank, this regulator benefits fuel pumps in several ways. The fuel pump will run
cooler, draw less current and will always have full volume output available at the pressure setting. The fuel return line runs between
the fuel return port of the regulator and the top of the fuel tank. The fuel tank must have
provisions for a fuel return line.
This regulator is equipped with a vacuum/boost compensation port (brass barb fitting) that can be used tomomentarily decrease
fuel pressure (vacuum compensation) at idle and part throttle, or increase fuel pressure under blower boost (boost compensation).
While it is not necessary to connect a hose to the vacuum/boost compensation port, it may be
beneficial in some cases. However, the small plug on the barb must be removed before use.
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1
MALLORY COMP PUMP® 110 AND 140
SERIES ELECTRIC FUEL PUMP SUGGESTED
MODIFICATION ONLY WHEN USING RETURN STYLE
REGULATORS(See Figure 1)
Step 1
Release the jam nut on the bypass plug. Remove the
bypass plug. Remove the bypass spring and plunger. Save
the bypass spring for possible future use.
Step 2
Inspect the bypass plunger. The bypass plunger surface
should be clean and slide freely in the chamber. Check
the bypass plunger pad and remove any debris embedded in its surface.
Step 3
Install the bypass plunger pad in the bypass plunger.
Install the bypass plunger and bypass spacer. Clean the
bypass plug.
Step 4
Apply thread sealant compound on the bypass plug.
You can find thread sealant compound at a hardware
store. Do not use thread sealing tape.
Step 5
Install the bypass plug. Gently tighten bypass plug until
you feel it lock (torque to 5 in/lbs). Install and tighten the
jam nut.
FIGURE 1
MOUNTING PROCEDURE
The regulator may be mounted at any angle. For maximum efficiency, mount the regulator as close as possible
to the carburetors.
DO NOT mount the regulator on or near exhaust manifolds. A bracket is provided for convenient mounting
under an intake bolt.
FITTINGS, FUEL LINES AND FUEL RETURN LINE
The fuel return line should be as large, or larger, as the
fuel line between the fuel pump and the regulator. See
Figure 3.
Purchase fittings (and plugs). Use a thread sealant
compound on the fitting threads. You can find thread
sealant compound at a hardware store. Do not use
thread sealing tape. Install the fittings. Do not overtighten the fittings. This could damage the regulator.
Connect the fuel lines and fuel return line. See Figure
3A-3C.
FIGURE 2
FUEL RETURN LINE SIZE
RECOMMENDATIONS
Fuel Return Line
Length/ Distance
16 – 20’
11 – 15’
6 – 10’
1 – 5’
3/8” = #6AN 1/2” = #8AN 5/8” = #10AN
FUEL PUMP GALLONS PER HOUR (FREE FLOW)
1 TO 99 100 TO 129 130 TO 199
1/2” 1/2” 5/8”
3/8” 1/2” 5/8”
3/8” 1/2” 1/2”
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