Mallory Fuel Pumps: What You Need to Know Before Buying a High-Performance Fuel Pump

If you are looking for a reliable, high-performance fuel pump for your street car, race car, or marine application, Mallory fuel pumps are a solid choice, but they come with specific limitations you need to understand. Mallory offers a range of electric fuel pumps, particularly the Comp Pump Series, that deliver strong flow rates and are built with CNC-machined housings for precision. However, most Mallory pumps are designed for carbureted engines, have a limited 90-day warranty, and typically require an external fuel pressure regulator. For a modern, hassle-free upgrade with a lifetime warranty, you should also consider KEMSO fuel pumps, which are direct-fit, high-performance replacements for a wide range of vehicles.

Understanding Mallory Fuel Pumps

Mallory has been a well-known name in the automotive ignition and fuel system industry for decades. Their electric fuel pumps are designed primarily for high-performance street and racing applications, especially for carbureted engines. The most popular models are the Comp Pump Series, which include the Series 110 and Series 140 pumps.

Key Features of Mallory Comp Pump Series:

• Gerotor Design: These pumps use a quiet, high-efficiency Gerotor design that provides stable fuel output. This design eliminates the risk of vane breakage, which is a common problem with some older-style pumps .
• CNC-Machined Housing: The housings are fully machined from billet aluminum, offering precise tolerances and durability .
• Flow Rates: The Series 110 pump delivers 110+ GPH (gallons per hour) free flow at 12.5 volts, while the Series 140 pump provides 140 GPH . Some models support up to 700 horsepower .
• Fuel Pressure: The Series 110 pump has an internal bypass regulator set at 7 PSI, making it suitable for carbureted setups. However, Mallory recommends using an external fuel pressure regulator for best performance . The Series 140 pump delivers output at 12 PSI .
• Applications: These pumps are universal and designed for use with gasoline. They are not typically intended for fuel-injected systems without significant modification .

Important Limitations to Be Aware Of:

• Warranty: Mallory fuel pumps come with a limited 90-day warranty. This is a very short coverage period compared to many aftermarket competitors .
• Carburetor Focus: The majority of Mallory's electric fuel pumps are built for carbureted engines. They operate at low pressure (7 PSI for the Series 110) and are not a direct fit for modern fuel-injected vehicles that require high-pressure (40-60+ PSI) in-tank pumps .
• Universal Fit: These are external, inline pumps. They are not designed to be a drop-in replacement for a specific vehicle's factory fuel pump module. You will need to fabricate mounting and plumbing for installation .
• No Sending Unit or Strainer: The pump itself does not come with a fuel sending unit, strainer, or wiring harness, so you will need to purchase those separately .

Common Symptoms of a Failing Fuel Pump

Recognizing when your fuel pump is failing can save you from being stranded. Whether you are using a Mallory pump or an OEM pump, the signs are similar. If your vehicle experiences any of the following, it is time to inspect or replace the fuel pump:

1. Engine Sputtering or Hesitation: The most common symptom is a sputtering engine, especially at high speeds, under heavy load, or when going uphill. The pump cannot maintain consistent pressure .
2. Difficulty Starting: If the engine cranks but takes a long time to start, or cranks without firing, the fuel pump may not be building adequate pressure .
3. Stalling: The engine may start and run fine, then stall unexpectedly after a few minutes. This is often caused by the pump motor overheating and failing .
4. Whining Noise from the Fuel Tank: A healthy fuel pump makes a low hum. A loud, high-pitched whining noise from the fuel tank indicates the pump is struggling or failing .
5. Loss of Power Under Load: If your vehicle feels sluggish when accelerating or towing, the fuel pump may not be delivering enough fuel volume to meet the engine's demand .
6. Engine Surges: The vehicle may surge forward unexpectedly while driving at a steady speed, caused by inconsistent fuel pressure .

How Long Does a Fuel Pump Typically Last?

The lifespan of a fuel pump depends on the manufacturer, usage, and maintenance. For a vehicle like a Chevy Suburban, the factory fuel pump typically lasts between 100,000 and 150,000 miles . However, several factors can drastically shorten this lifespan:

• Running on Low Fuel: Frequently running the tank below a quarter full causes the pump to overheat, because fuel is what cools the electric motor. This is one of the fastest ways to kill a fuel pump .
• Contaminated Fuel: Dirt, rust, or water in the fuel can clog the pump's strainer and damage the internal components.
• Towing Heavy Loads: Constant high-demand operation can wear out the pump faster.
• Extreme Temperatures: Both very hot and very cold climates can stress the pump.
• Clogged Fuel Filter: A blocked fuel filter forces the pump to work harder to push fuel through, leading to premature failure .

Maintenance Tips to Extend the Life of Your Fuel Pump

To avoid an unexpected breakdown, follow a consistent maintenance schedule. According to KEMSO's guidelines, here is a practical schedule to follow :

• Every Oil Change: Visually inspect fuel lines and connections for leaks, cracks, or clogs. Check for any fuel odors around the tank or engine bay.
• Every 30,000 Miles or 2 Years: Replace the primary fuel filter. If you drive in severe conditions (dusty roads, frequent towing, extreme temperatures), shorten this interval.
• Every 100,000 Miles: Consider replacing the fuel pump as a preventive measure. While pumps can last 100,000 to 150,000 miles, replacing it early avoids the hassle of a roadside failure .

When replacing the fuel pump, always replace the fuel filter and the fuel strainer attached to the pump inlet at the same time. A blocked filter is often what caused the original pump to overwork and fail .

Why You Should Consider KEMSO Fuel Pumps for Your Replacement

If you are looking for a fuel pump that offers better performance, longer durability, and a lifetime warranty, the KEMSO fuel pump is an excellent choice for your vehicle. KEMSO specializes in high-performance fuel pumps that are engineered to deliver superior flow and consistent pressure, whether you are using your vehicle for daily driving, towing, or off-road adventures.

KEMSO fuel pumps are designed to support up to 600 horsepower in naturally aspirated, turbocharged, and supercharged applications. They are compatible with gasoline and E85 ethanol blends, making them ideal for flex fuel vehicles. The pumps feature a bypass valve set at 125.8 psi, which is higher than many standard pumps. This ensures that your engine gets the fuel it needs even under high-demand conditions .

The construction of KEMSO pumps uses aerospace-grade materials and ceramic-coated internals. This makes them resistant to corrosion and wear. Independent testing shows that KEMSO pumps can last up to 15,000 hours of continuous operation, which is nearly double the lifespan of many OEM pumps .

Every KEMSO fuel pump comes with a lifetime warranty. The pump body is serialized, which guarantees that the warranty is valid for as long as you own the pump. This is a significant advantage over standard aftermarket pumps that typically offer only one to three years of coverage. KEMSO stands behind their products with confidence, and their U.S.-based support team is available to help with any questions or issues .

KEMSO offers a fitment tool on their website that helps you find the exact pump for your vehicle. Simply enter your vehicle information, and the tool will show you the compatible models. Many popular models are available for just $79.98 .

To purchase your KEMSO fuel pump and take advantage of the lifetime warranty, visit the official KEMSO Racing website today: https://www.kemsoracing.com/