Mallory Ignition 5160FI User Manual

FORM 1552M 04/05

INSTALLATION INSTRUCTIONS

COMP PUMP®SERIES 160FI ELECTRIC

FUEL PUMP PART NO. 5160FI

DO NOT RUN THIS PUMP WITHOUT FUEL

(EXCEPT FOR BRIEF PERIODS WHILE PRIMING).

Parts Included in this kit

1 COMP PUMP® 160FI Series Electric Fuel Pump
2 Fittings, 3/4-16 x #8 AN Flare
2 O-rings, Nitrile 0.644ID x 0.087THK

GENERAL INFORMATION

The COMP PUMP® 160FI Series Electric Fuel Pump is a
high pressure fuel pump designed for fuel injection applica­tions. In all cases, this fuel pump must be used with a
return style (bypass) fuel pressure regulator. Using the pump
with any other type of regulator (or no regulator) will result in
severe fuel pump damage. We recommend the following
return style fuel pressure regulators:

4–25 PSI Part No. 4307M (gasoline or alcohol)
30–100 PSI Part No. 4305M (gasoline or alcohol)

You must install a fuel return line between the fuel return
port of the regulator and the fuel tank. We recommend at
minimum a #8 AN (1/2”) fuel return line.

Be sure to install a suitable fuel filter (max. 100 micron)
between the fuel tank and the fuel pump, such as the
Mallory COMP FILTER® Series Part Nos. 3140, 3500, or

3175. This prevents debris from becoming wedged in the
fuel pump’s gears and locking it.

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

This pump is assembled with the inlet port on the right and
the outlet on the left. However, by loosening the bolt on the
clamp portion of the coupler housing, the lower pump
housing can be rotated so that the inlet is on the opposite
side (see Figure 4).

SPECIFICATIONS

Maximum recommended operating pressure:
60 PSI continuous, 100 PSI intermittent
Fuel pump thread sizes: Inlet/outlet, 3/4-16 (#8AN)
Recommended fuel line size: 1/2” (or #8AN)
Current draw: 14 AMP Typical
Oil pressure switch rating: 25 AMP
Fuel pump over current protection: 25 AMP fuse
Fuel application: Gasoline or Alcohol

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.

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. NOTE: Pump
may be mounted at any angle.

Step 3

Connect 1/2” (or –8AN) or larger fuel lines as shown in
Figure 1.

Step 4

Your system must have a Return Style Fuel Pressure
Regulator near the injection system. 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 installed just before or just
after the fuel injection.

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FIGURE 1

12V

WIRING PROCEDURE

Wiring a 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 12 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.

FIGURE 2

FIGURE 3

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