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 SPECIFICATIONS 1 2 2 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 COMP PUMP® 160FI Series Electric Fuel Pump Fittings, 3/4-16 x #8 AN Flare O-rings, Nitrile 0.644ID x 0.087THK GENERAL INFORMATION MOUNTING PROCEDURE 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: 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. 4–25 PSI Part No. 4307M (gasoline or alcohol) Step 2 30–100 PSI Part No. 4305M (gasoline or alcohol) 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. 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. Step 3 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. 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. 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). MALLORY IGNITION Connect 1/2” (or –8AN) or larger fuel lines as shown in Figure 1. Step 4 www.malloryracing.com 1 FIGURE 1 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 12V FIGURE 3 2 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. www.malloryracing.com MALLORY IGNITION FIGURE 4 MALLORY IGNITION ITEM NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. www.malloryracing.com DESCRIPTION Lower Pump Housing Clamp Bolt Coupler Housing Coupler Gasket, Bracket Vibration Bracket Nut, Motor Housing (2) Adapter, Motor Washer, Spring Screw, Motor Adapter (2) Motor 3 MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP 10601 MEMPHIS AVE. #12, CLEVELAND, OH 44144 216.688.8300 FAX 216.688.8306 www.malloryracing.com MALLORY IGNITION www.malloryracing.com FORM 1552M 04/05 Made in U.S.A. Printed in U.S.A. 4