BD Diesel Performance FlowMAX Lift Pump V3 User manual

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 1 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
1998.5-02 DODGE CUMMINS 24V ISB
F
FL LO OW WM MA AX X L LI IF FT T P PU UM MP P K KI IT T
I n s t a l l a t i o n I n s t r u c t i o n s
Part# 1050301D
PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
This pumps idle pressure will be 17-19 psi, rather than 13-15 psi.
DOWNLOAD ENHANCED
INSTALL MANUALS AT
dieselperformance.com

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 2 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
Kit Contents
1500365-P1
1402609
1500357
1900015
1500355
FLOWMAX Lift Pump V3
M8 Flat
Washer
3/8” Flat
Washer
Flange
M8x30mm
Pump Bracket
Qty: 1
Qty: 3
Qty: 3
Qty: 3
Qty: 1
1500356
1300529
1505001
1500359
1500311
FlowMAX Anti-
Vibration Mount
Self Tapping
Screw
Hose Clamp
Self Threading
3/8” Bolt
-AN 8 ORB x 3/8” Barb
Qty: 3
Qty: 1
Qty: 5
Qty: 3
Qty: 1
1500310-D
1502033
1604053
FlowMAX Lift Pump Wiring Harness
M12 x -8 JICM Adapter
3/8” Fuel Hose
Qty: 1
Qty: 1
Qty: 78”
1502034
1500358
1500311-M
-8 JICF x 3/8” 90° ADAPTER
T-Bolt Clamp
Filter Fitting
Qty:1
Qty: 2
Qty: 1

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 3 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
1500372
1500392
Flowmax Bracket (box frame)
Mount Strap 20.7”
Qty: 1
Qty: 2
Before You Begin
The FlowMax pump is designed to be a stand-alone pump system and is not
designed to be used in conjunction with stock lift pumps. If your truck has been
retrofitted with the Chrysler in-tank lift pump you will have to lower the fuel tank &
delete the pump from in the tank. BD offers a simple retrofit kit complete with
instructions & the pieces needed to do this, part number 1050302. If you are unsure
if your truck has been retrofitted simply check that the factory lift pump is still in
place on the engine next to the fuel filter housing (see diagram on pages 9 & 10); if it
is not there then your truck has the in-tank pump.
Optional Accessories
1081130 - Low Fuel Pressure LED Alarm kit
1050350 –Water in Fuel Sensor Kit (2000-07)
Required Tools:
5mm Allen wrench
Drill
1/8” and 11/32” Drill bits
Pliers
3/16” Flat Screwdriver
10 mm Socket or wrench
Small Pipe Cutter
Knife To Cut Fuel Hose
9/16” Socket or Wrench
7/16” Socket or Wrench
Installation
1. Disconnect both batteries.
2. Raise the vehicle and support it safely.
3. Unbolt the front driveshaft (4x4 only) for ease of installation.

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 4 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
Mounting Option 1 - Mounting Bracket using straps
4. Find a suitable place to mount the bracket to the inside of the frame; closest to the
fuel tank. Avoid mounting where the bracket could rub on fuel lines, break lines and
cables. Install straps around frame and bracket and torque to 80-90 in/lbs.
NOTE: The Nylock nut must be on the
opposite side of the frame from the bracket.
You will also need to cut a section of the
supplied hose length wise (one side only)
to go over the fuel lines to protect them
from rubbing against the band straps,
secure with cable ties and ensure there is
no metal to metal rubbing.
Fuel line
Hose
Align strap
close to tabs
Note orientation
of bracket
Inside of frame

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 5 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
5. Insert the three rubber isolators into
the support bracket. Use some
water to aid in lubricating the
isolators as the slide into the bracket.
Place the large washers on the inside
of the bracket against the rubber
isolator.
Tighten the supplied M8 bolts
through each vibration isolator of the
support bracket and into mounting
bracket (PEM) nut. Repeat this step
for the other 2 bolts.
Torque the three bolts to 10-14ft-lbs.
Straps & Frame
Not shown
Bolts
Mounting bracket
Isolator
Support Bracket
Washer

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 6 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
Mounting Option 2 - Mounting the Pump Bracket to the Frame
4. From underneath the vehicle
locate the cross member
bracket on the inside of the
driver’s frame rail. Position
and tape drill template (from
the back of this manual) onto
the frame rail just above the
weld. Place fuel pump and
bracket in place to ensure
ample clearance.
Mark holes with center punch.
Remove drill template and
drill pilot holes to 1/8”. Drill
main holes to 21/64”.
5. Insert the three rubber
isolators (1500356) into the
support bracket. Use some
water to aid in lubricating the
isolators as the slide into the
bracket.
Place the large washers
(1500357) on the inside of the
bracket against the rubber
isolator.
Using a air ratchet (9/16”
socket) tighten the self-
threading 3/8” bolt (1500359)
through each hole if the
support bracket assembly and
into the frame. Repeat this
step for the other 2 bolts.
Torque the three bolts to
25ft-lbs

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 7 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
6. Locate the two supplied T Bolt
band clamps; unthread the nut
(7/16” Socket) from each of
them. Spread the clamps apart
and insert them through boxed
cutouts.
With both clamps inserted, place
the pump into place and align the
inlet and outlet parallel to the
frame.
The inlet should be pointed
towards the fuel tank.
Tighten the clamps around the
motor body, rather than the
aluminum pump head. Torque
nuts to 80 in-lbs.
7. Insert the Filter fitting (1500311-M)
into the (IN) side of the pump and
the ORB fitting (1500311) into the
outlet of the pump. Do not over
tighten as they use an o-ring for
sealing.
NOTE: If installing a filter kit, skip this
step and refer to the Flomax Filter Kit
manual for the install procedure for the
water separator and fuel filter. Once
Filter install is complete; continue to
step 8.
FITTING
FITTING

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 8 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
8. Install rubber hose (1604053) onto the (IN) side of the pump secure using the
supplied hose clamp. Locate a section of fuel supply hard line close to the
stock fuel line clamp and skid plate. Cut the hard line a few inches away using
a tube cutter and install the rubber hose from the pump onto the hard line and
secure using two of the supplied hose clamps. NOTE: the remaining hose will
be used for the (OUT) side of the pump to the fuel bowl connections.
**CAUTION** Diesel fuel will spill out of line when cut.

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 9 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
9. Remove the stock lift pump from the side of the engine along with fuel line
back to where the line was cut along the frame rail and up to the fuel filter
bowl. At the fuel bowl the banjo bolt will need to be removed as well since it
is being replaced.
1502033
1502034
Washer
2003
+

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 10 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
1998.5-1999 Trucks Only
2000-2002 Trucks Only

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 11 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
10. Thread the JICM adapter (1502033) into the fuel filter bowl and tighten
first. Do not over-torque as this is an o-ring seal. Then thread on the JICF
adapter (1502034) position the barbed end and tighten.
Note the JICM adapter has a loose washer around the oring ensure this does not
fall off the adapter during installation. The remainder of fuel line is then run from
the fuel filter bowl down to the fuel pump, with one clamp on the filter bowl
adapter assembly and one on the fuel pump fitting, making sure to run the line to
the outlet (OUT) side of the pump. Remove the excess fuel line prior to installing
on outlet and clamping.
1998.5-99
Top of filter housing
2000-02
Rear of filter housing
Fuel Bowl Fitting

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 12 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
11. Lay out the wiring harness so that it can be plugged into the stock fuel
pump harness, plug into the new FlowMAX Fuel Pump, and place the positive
and negative terminals in their approximate routing. Once the routing paths
have been chosen and laid out, install the relay to the firewall with the use of
self tapping screw.

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 13 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
12. Wiring should be attached with the use of supplied tie wraps so that the
wiring will be away from contacting hot surfaces and/or moving components.
Once the wiring is attached and everything is in place the positive and
negative terminals can be attached to the battery.
13. Make sure that all fuel lines, wiring harness’ are fixed in place well.
14. Re-install the front driveshaft (4x4 models only).
15. Lower the vehicle, and re-install the battery cables.
The pump will develop 15-18psi at idle with 14VDC. If your battery voltage is
lower so will the pressure.
Flow Specifications
Flowrate should be MINIMUM 2.5GPM(150GPH) @ 14VDC
OR
Filling a 1 gallon container every 24 seconds @ 14VDC

3 October 2016 # 1050301D 1998.5-2002 Dodge Cummins FlowMAX Lift Pump Kit (I-00167) - 14 -
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
Trouble Shooting
If you experience any problems or difficulties with this kit, please contact the BD
Technical Department at 1-604-853-6096 or fax at 1-604-853-8749, between
8:00am and 4:30pm Pacific Time.