FUEL RETURN LINE SIZE

RECOMMENDATIONS

Fuel Return Line

Length/ Distance

16 – 20’

11 – 15’

6 – 10’

1 – 5’

FUEL PUMP GALLONS PER HOUR (FREE FLOW)

1 TO 99

100 TO 129

130 TO 199

1/2î

1/2 ”

5/8”

3/8”

1/2”

5/8”

3/8”

1/2”

1/2”

3/8” = #6AN

1/2” = #8AN

5/8” = #10AN

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 sur-

face 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 Teflon 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.

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

Teflon 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.

2

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MALLORY IGNITION

FIGURE 1

FIGURE 2