BD Diesel Performance FlowMAX Lift Pump V3 User manual

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
2003-04½ DODGE CUMMINS
B
BD D F FL LO OW WM MA AX X L LI IF FT T P PU UM MP P K KI IT T
Installation Instructions
P/N#
1050305D
PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
The BD auxiliary lift pump kit will provide the safety and performance of enhanced fuel flow to your
Cummins engine. This pumps idle pressure will be 17-19 psi, rather than 13-15 psi.

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
1500358
1500355
FlowMAX Lift Pump V3
T-Bolt Clamp
Mounting Bracket
Qty: 1
Qty: 2
Qty: 1
1500356
1604110
1900015
1500310-D
FlowMAX Anti-
Vibration Mount
Elbow Fitting
1/4” NPT – 3/8”
barb
Flange M8
X 30mm
FlowMAX Pump Wiring Harness
Qty: 3
Qty:1
Qty: 3
Qty: 1
1604053
1500311
1500311-M
3/8 Fuel Hose
-AN 8 ORB x 3/8” Barb
Filter Fitting
Qty: 84
Qty: 1
Qty: 1

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
1402609
1500357
1500359
1505001
1502028
1502029
1300529
M8 Flat
Washer
3/8” Flat
Washer
Self
Threading
3/8” Bolt
Hose Clamp
OEM Lift
Pump
Adapter
O-Ring
Self
Tapping
Screw
Qty: 3
Qty: 3
Qty: 3
Qty: 5
Qty: 1
Qty: 1
Qty: 1
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 page 4); if it is not
there then your truck has the in-tank pump.
Optional Accessories:
1081130 - Low Fuel Pressure LED Alarm kit
1050340-WSP –Water Separator with Head Kit
1050340-PFF –Post filter with Filter Head Kit
1050350 –Water in Fuel Sensor.
Required Tools:
5mm Allen wrench
Drill
1/8” and 21/64” Drill
bits
Pliers
3/16” Flat Screwdriver
9/16” Socket or
Wrench
10 mm Socket or wrench
Small Pipe Cutter
Knife To Cut Fuel Hose
7/16” Socket or Wrench

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
Installation
1. Disconnect both batteries.
2. Raise the vehicle and support it safely.
3. Locate and remove the factory lift pump. The pump is supported by four, 5mm
socket cap screws.
4. Install the brass 90° NPT to barb fitting into the supplied aluminum pump bypass
bracket. The brass elbow should be orientated so that the barbed end points
down or oriented 90° to the mounting holes. You will need to use Teflon sealant
to seal the threads.
5. Install the new o-ring on the fuel filter
end of the adapter. Be sure to
lubricate the o-ring before installing.
6. Position and press the bypass
adapter onto fuel filter housing. Do
not use mounting bolts to draw
bypass adapter in to the filter
housing.
7. Be sure the bypass adapter is
positioned flat to the fuel filter
housing. Install mounting bolts and
evenly tighten to 7 N·m (61 in. lbs).
8. Connect one end of the supplied fuel line to the brass barb fitting and run it
down the frame rail to where the Flomax pump will be mounted. The existing
factory fuel line will not be used between the Flomax and the fuel filter housing.
Make sure that the hose won’t rub on anything or come to close to major heat
sources. You can clamp or plug off this line during the rest of the installation to
prevent fuel from being siphoned out of the fuel filter.

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
Mounting Option 1 - Mounting Bracket using straps
9. 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.
10. Insert the three rubber isolators
into the support bracket. Use
some water to aid in lubricating
the isolators as they 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
Align strap
close to tabs
Note orientation
of bracket
Inside of frame

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
9. 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”.
10. 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

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
11. 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 pump inlet ”IN” and
fuel filter are pointed to
the tank fuel pickup.
Tighten the clamps
around the motor body,
as seen in photo.
Do not tighten clamps
around the pump end
caps as seen in the two
bottom photos. Make
sure the clamps are
evenly spaced on the
motor body.
Torque nuts to no more
than 72 in-lbs.
Insert clamp
through cutout
Insert clamp
through cutout

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
12. 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 13.
13. With the pump
mounted, cut the hard
fuel line about 12”
from the outlet side of
the pump on the
inside of the frame
rail. The fuel supply
line is the thickest of
all three lines. Discard
the remainder/cut
portion of the cut fuel
line.
A tube cutter does not
need to be used for
this cut.
Fitting
Fitting

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
14. Trim and connect the 3/8” fuel hose from step 8 to the outlet of the pump. Use
a hose clamp to secure this connection. The remainder of the hose will be used
for the inlet of the pump.
15. Cut the hard fuel supply
line once again, this time
about 8” before the inlet of
the pump. This time you
will need to use a tube
cutter.
Install a small section of
hose to the hard line.
Then to the pump inlet
which will be on the other
side of the frame rail.

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
16. Secure each connection
with a hose clamp. Use
two hose clamps when
securing the rubber hose
to the hard line.
17. 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.

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
18. 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.
19. Make certain that all fuel lines, wiring harness’ are fixed in place well.
20.Lower the vehicle and re-install the battery cables.
21.Take the truck for a test drive and measure pump output pressures. The pump
pressure sure idle at 17-19 psi.
Flow Specifications
Flowrate should be MINIMUM 2.5GPM(150GPH) @ 14VDC
OR
Filling a 1 gallon container every 24 seconds @ 14VDC

15 June 2016 #1050305D 2003-2004½ Dodge Cummins FlowMAX Lift Pump Kit (I-00169) - 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
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.