Mallory Ignition Mallory 3-PORT COMPETITION FUEL PRESSURE REGULATOR (RETURN STYLE) 4309 - Manual (Page 2)

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
1/2” 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 surface
should be clean and slide freely in the chamber. Check
the bypass plunger pad and remove any debris embed-
ded 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.
MOUNTING PROCEDURE
The regulator may be mounted at any angle. For maxi-
mum efficiency, mount the regulator as close as possible
to the carburetors.
DO NOT mount the regulator on or near exhaust mani-
folds. 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 over-
tighten the fittings. This could damage the regulator.
Connect the fuel lines and fuel return line. See Figure
3A-3C.
2 www.mallory-ignition.com MALLORY IGNITION
FIGURE 1
FIGURE 2