MAINTENANCE –
PUMP DISASSEMBLY
If your pump fails to produce adequate pressure or
volume, it may require cleaning. Follow the steps below to
disassemble and clean your Mallory Electric Fuel Pump.
Refer to Figure 6 while performing the following steps.
Step 1
Remove the pump from the vehicle and clean pump exterior.
Place the pump on its side on a clean work surface. Scribe
or draw a line across the pump housing, port plate and fuel
chamber so that you can reassemble the pump correctly.
Step 2
Remove the two fuel chamber screws from the bottom of the
pump. Remove fuel chamber and port plate from the pump.
NOTE: Do not drop the gerotor from the pump cavity.
Step 3
Place your hand beneath the gerotor and hold the pump in
an upright position. The gerotor should slide out of the
pump and into your hand.
Step 4
To disassemble the fuel chamber, first remove the lock nut
and adjusting screw, then turn the fuel chamber over so that
the diaphragm spring falls into your hand. Remove the four
screws holding the diaphragm cap to the fuel chamber.
Remove the diaphragm cap, diaphragm, and damper spring
from the fuel chamber.
Step 5
Clean the gerotor and reinstall it in the pump housing.
Inspect the O-ring and gasket, and replace them if
necessary. Inspect the diaphragm for any small tears or
bubbles in the surface, and replace it if necessary. Inspect
the gerotor housing and port plate for wear. If the generator
has worn through the plating, return the pump to Mallory
for repair.
Step 6
Assemble the pump in the reverse order that you
disassembled it. Test bypass pressure. Adjust bypass
so that pump is producing between 13 and 20 psi.
17
16
24
15
14
13
22
12
21
23
1.
2.
*3.
*4.
5.
*6.
*7.
*8.
9.
*10.
11.
12.
*13.
*14.
*15.
16.
*17.
*18.
19.
20.
21.
22.
23.
24.
20
19
11
10
18
9
7
8
FIGURE 6
6
5
4
JAM NUT
ADJUSTING SCREW
PRESSURE ADJUSTMENT SPRING
CAP SCREW (4)
REGULATOR CAP
GASOLINE DIAPHRAGM
ALCOHOL/METHANOL DIAPHRAGM
FUEL CHAMBER SCREW
DAMPER SPRING
FUEL CHAMBER
FUEL CHAMBER GASKET
PORT PLATE
GEROTOR
GEROTOR BUSHING KEY
GEROTOR BUSHING
O-RING
GEROTOR HOUSING
SEAL
BRACKET VIBRATION GASKET
BRACKET
MOTOR HOUSING NUT (2)
MOTOR ADAPTER
SPRING WASHER
MOTOR ADAPTER SCREW (2)
MOTOR
3
*THESE PARTS ARE INCLUDED IN SEAL / DIAPHRAGM KITS
PART NO. 3171 FOR GASOLINE
PART NO. 3172 FOR ALCOHOL
2
1
IMPORTANT:
Turn fuel chamber screws by hand until they
contact the chamber. Then torque to 24 inch/pounds
MALLORY IS A DIVISION OF THE MR. GASKET PERFORMANCE GROUP
10601 MEMPHIS AVE. #12, CLEVELAND, OH 44144
216.688.8300FAX 216.688.8306
FORM 1038
(REV. F) 11/04
Made in U.S.A.
Printed in U.S.A.
www.mrgasket.com
4
MALLORY [ MALLORY PERFORMANCE CLUB ]
