Mallory 4140M Installed

[Jetpilot]

Got the Mallory pump in tonight, new 3/8 fuel lines from the tank to the OEM fuel filter + Ray's banjo bolts. I installed the Mallory pump back by the fuel tank outlet on the outside of the frame with a Mallory 200 GPH prefilter.



Took the truck out for a spin and could still drag down the fuel pressure to zero (with the UFM set on 5X5), although it takes alot longer now than before with the stock setup. The pump idles at 16-17 PSI and cruises down the highway at around 12 PSI. So I went home and replaced the OEM fuel filter but the results are the same. The good news is that with the fueling box turned off the fuel pressure doesn't drop below 5-6 PSI (the stock lift pump went to zero in just a few seconds).



Guess now I will need to replace that puny little line from the OEM fuel filter to the VP44 with something larger. I have been talking with HVAC prior to installing the pump and he thought the banjo's and the small line between the OEM fuel filter and the VP44 would be a problem.



If anyone has any other ideas please let me know..... Thanks.



Doug

 

[Bigsaint]

Doug, I'm surprised that your WOT readings are that low with the Mallory set at 17 psi's idle. I have my Mallory set at 13 psi's post filter @ idle and can't drop it below 5-6 psi's at WOT with the TST box. That's with the step 5 injectors also. The only difference between our set ups is that I lost all the banjos and went with the Weber adapters and the Aeroquip elbows. Give Brandon a shout at his shop 209-578-1850. He can set you up with a short length of braided SS line, 2 Weber adapters to replace those banjo bolts and a pressure port for the gauge. That should open up the flow .



Scott W.

 

[Jetpilot]

Scott,



Boy was I surprised too! I thought that I would not be able to full down the fuel pressure like I can..... I also believe the problems are the 3 banjos that are left in the system + the small fuel line from the fuel filter to the VP44.



What kind of fitting can I put on the inlet side of the OEM fuel filter an have it attach to 3/8 rubber fuel tubing that is better than the banjo? I haven't worked with SS line or these type fittings before so I really don't know the in's and out's on them. On the oulet side of the fuel filter I think you are correct that braided SS line + Weber adapters and Aeroquip elbows are the way to go. I am considering all SS line back to the fuel tank but I am trynig to conserve some $$ since a new turbo is on the way. Also I have only one usable hand right now, oh well doc says it will be good as new in another 5 weeks, 3 days, and 6hours, 23mins, 18seconds... ... But who is counting!

 

[John]

Personally, I feel the restriction in the system is with the OE fuel filter assembly. I have Aeroquip -06 AN AQP hose from the fuel sending module to my System 1 prefilter, to my Mallory 4140M fuel pump, directly to my OE fuel filter and finally, to my VP44... in other words, no stone was left unturned. With all my testing so far I feel modification of the OE fuel filter assembly is warranted if increased system flow is a primary objective.

 

[Jetpilot]

John,



I agree that the OEM fuel filter is not the optimum for fuel flow. But looking at it with my unqualified eyes I would think it would be able to pass enough fuel to not let the fuel pressure drop to zero. I am going to try larger fuel lines between the OEM fuel filter and the VP44 and also eliminate the banjo bolts associated with this fuel line. Do you know if I can hook a weber type fitting to a 3/8 rubber fuel line? I would like to eliminate that banjo bolt as well.



I have spoken via email with massdiesel about his mods to the OEM filter and may pursue improvement with the OEM fuel filter if the fuel line and removal of the banjo bolts does not result in acceptable pressure. I would think that there has to be a better fuel filter setup out there already, we just need to find it!



Thanks,



Doug

 

[HeberRam]

Mallory?

Guys ... . need to ask a few questions? Are you using the Mallory 4140M fuel pump and bi-passing or replacing the stock lift fuel pump? If so, what is the Mallory 4140M rated at in terms of fuel pressure and GPM/ Hour? The reason I'm asking is I have an inline pusher pump with the stock lift pump and have simular mods, and run 17-18psi at idle and can't get below 13psi wot!

 

[Jetpilot]

HerberRam,



The Mallory is a pump that is good to about 20 psi and is rated @ 140 GPH. The stock lift pump is bypassed. I ran new 3/8 fuel line from my tank outlet to a Mallory pre-filter (rated @ 200 GPH) to the 4140m, then direct to the OEM fuel filter. The stock banjo bolts have been replaced with Rays larger banjo bolts.



I may get some #'s off a bit here but with the stock lift I could go to 0 psi with just the injectors. I also believe that this was the results Bill K. got when he installed the super mental injectors. Now I can hold 3-5 psi with the UFM on level 4 (prior it was 0 real fast). It is only on level 5 of the Hot UFM that I go to 0. HVAC thought that I would need to replace the banjos + the small fuel line from the OEM filter to the vp44 prior to starting the upgrade.



The sm injectors really can pass a ton of fuel through them! Don't know how they flow compared to BD5's but I wouldn't give them up! Now just got to get the setup complete so I will be all set when the new turbo arrives... .

 

[Bigsaint]

Herber, actually, according to my good friend DieselB59, the Mallory will put out 40 psi's when tightened all the way in (dead head adjustment on the pump). Chris is running a Mallory 140 series in place of the mech. lift pump on his 12 valver and has been doing so since last spring. While we 24 valvers don't need that much, it' s real nice to be able to adjust the pump at will for more or less.



Doug, personally, I'd just go with the Braided line and Weber adapters/Aeroquip elbows for the whole in bound system, my outbound(return lines) are still stock and I see no reason to change them. You are not really talking about a huge some of money, maybe around $150. 00 or a bit more with the pressure port adapters. You would also need a Earl's compression fitting to adapt to the hardline by the tank and two 3/8"NPT to -6AN fittings for the pump itself. You could give Brandon a call for a price quote or just put a list together and get the parts from Summit Racing or Jegs, both have online cat's.



I never worked with braided line before either, for that matter never even seen it in person before I did mine. I had ordered the fuel line upgrade from Brandon and once I saw how great it looked, I decided to put it in from the tank to the VP44. It's not hard to work with, you simply measure and cut the line to your desired length ( you must wrap the area that you are going to cut with tape, I just used black electrical tape) and cut it with a high speed blade ( I used a Dremel tool as I didn't have access to a air cut off tool at the time). You then apply some oil to the line and press on the elbow or hose end and tighten it down. It's really easy and I'm sure you can do it if you managed to get that pump installed with one hand .



Something to consider, anywho. If nothing else, try that line and fitting upgrade from the filter to the VP44 for now, it sure won't hurt anything and will defintely improve your flow. I have to agree that the filter is a major restriction, but I'm not convinced that it's a mandatory upgrade, even with the shower head injectors as my psi's never come close to zero and my pump is set at lower psi's than yours. Not sure on the flow of the supermentals V. the BD 5's, but I'd take a guess that they are real close.



Just for testing, , I took another WOT run today with the TST comp. set on 'KILL', post filter psi's never went below 5.



Scott W.

 

[Bigsaint]

Forgot to add... you could still use that existing rubber fuel line going back from the inlet to the fuel filter canister to the Mallory with the Weber fitting in replacement of the banjo. The Weber has a -6AN male fitting that you could adapt to the 3/8" line like so... -6AN female to female coupler, -6AN to 3/8"NPT fitting and then a 3/8" female fitting to 3/8" hose barb, which you would then slide the rubber line onto. If you want to try this route first to save some $$$, send me a PM and I'll put together a parts list from Summit or Jegs, your choice. This would be considerably less $$ as the braided line is expensive. It would also save you the expense of the pump fittings and the compression fitting for the hardline. The fittings aren't cheap either.



Scott W.

 

[HeberRam]

Thanks Guys!

Thanks, for the info guys... I didn't know the mallory had a built-in pressure regulator! I need to find a pressure regulator to get my pressure down to a readable range of my fuel gauge 15psi at idle. I'm also running super mentals, have plenty of pressure but don't want to exceed 15psi at idle. thanks, again

 

[Mark_Kendrick]

Is there any where to get a complete parts listing for this project?



I've been reading about it long enough that I think I'm gonna do It when I get my injectors and B1.



I live in BFE and want to get everything in advance.



BigSaint. . watch your email

 

[John]

Scott, you are correct about the pressure capabilities of the Mallory 4140M... while returning my Mallory 4140M to its pre-"upgraded/experimental" state, I had to reset the pressure. During the process I achieved 30 psi briefly while "ballpark" adjusting it. I quiclky reduced this to 18-19 psi which has stabilized at 17 psi.



BTW, the Aeroquip AQP hose I used throughout my entire fuel system consists of a braided stainless jacket over a neoprene type core. Aluminum Aeroquip fittings were also used throughout, including the trick Weber adapter fittings. I have no banjo fittings on the fuel delivery system of my Ram... I removed all of them way over a year ago.

 

[PatrickCampbell]

I want to run tank -> Racor 6120R (120 GPH fuel filter/water seperator) -> dual Carter pumps plumbed in parallel -> VP44.



What do I need to do to run from the tank to the Racor ... ... (3/8" NPT on that end)...

 

[DTrent]

boost pump "mallory

Are you guys using a pressure regulator in line with your mallory 140 pump ?

 

[Todd T]

DTrent this is a pretty old thread and i believe Jetpilot has even moved away from this pump. To answer your question, YES.



you should regulate down to the high teens at the most. its not real good to have too much pressure on the inlet of the VP or the stock filter housing for that matter. and you should never drop below 4-5PSI under full load.

 

[DTrent]

The pressure regulator that came with the pump has a max psi range of 9 psi. This is why I wondered if I should use it or buy something with a larger range. I think the paper work on the pump said it was factory set at 12 psi.



Thanks for the reply Todd T.

 

[Todd T]

NO problem. i believe you can tweak the pump's setting too. sounds like you have your answer on the regulator though (9psi is not enough)

 

[Huff N Puff]

Doug if you are over over 500hp you need to open up the line from the tank to the suction side of the pump. The stock fuel line is to small to flow 200gph. You are throttling the suction side. Merv