BD Diesel Performance Flow-MAX User manual

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
2013-17 RAM Lift Pump Kit
Installation Instructions
P/N#
1050312D
PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION
DOWNLOAD ENHANCED
INSTALL MANUALS AT
dieselperformance.com

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
1500331
FlowMax Lift Pump V3
FlowMax Wiring Harness 2013-2016 Dodge
Qty: 1
Qty: 1
1500419
1500418
1604053
1330175
3/8" Quick Connect Female
3/8" Quick Connect Male
3/8" Fuel Hose
5/8” ID Protective Loom
Qty: 1
Qty: 1
Qty: 136”
Qty: 112”
1500311-M
1500311
1505001
Filter Fitting x 3/8” Barb
-AN 8 ORB x 3/8” Barb
Hose Clamp
Qty: 1
Qty: 1
Qty: 5
1500358
1500355
1500392
1500372
T-Bolt Clamp (Pump Body)
Mounting Bracket
Mount Strap 20.7”
Flowmax Bracket
Qty: 2
Qty: 1
Qty: 2
Qty: 1

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
1500356
1300529
1300131
Vibration Isolator
Self-Tapping Screw
Tie Wrap
Qty: 3
Qty: 1
Qty: 12
1900015
1402609
1500359
1500357
Flange M8 x 30mm Bolt
M8 Flat Washer
Self-Threading 3/8” Bolt
3/8” Flat Washer
Qty: 3
Qty: 3
Qty: 3
Qty: 3
1462115
1601522
1130058
FT-90700
3/4” Insulated Clamp
M6 Flat Washer
Nylon Locking Nut M6x1
Flange Nut M6x1
Qty: 2
Qty: 2
Qty: 2
Qty: 1
Introduction
The 2013-2016 RAM trucks with the 6.7L Cummins engine have a stock in-tank fuel
pump capable of delivering enough fuel to support stock horsepower and mild engine
modifications. For higher horsepower, more fuel supply is required and a high flow fuel
pump is required.
The BD Diesel FlowMax fuel lift pump is a high performance upgrade for your trucks
fuel system that eliminates the factory fuel limitation. This lift pump can supply up to
150 gph of fuel, enough to support 600 horsepower.
Installing this kit is now easier thanks to the supplied quick connect fuel fittings which
eliminate cutting the factory steel lines. This kit comes with 3/8”
fuel line and fittings to connect to the factory system. See the
next page for a list of optional accessories that can be used to
get even more from your fuel system including 1/2" fuel line,
draw straws, fuel bowl deletes, etc.
The FlowMax V3 pumps are a high longevity gerotor design
which results in low noise and high reliability.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Optional Accessories
1050340-WSP Water Separator Add-on Kit
This kit adds a high micron (low pressure loss) filter to the inlet of
the pump with integral water separator and drain. This is strongly
recommended if removing the stock filter next to the fuel tank.
1050340-FPP Fine Filter Add-on Kit
This kit adds a low micron filter to the outlet of the pump. This is
recommended when bypassing the factory fuel filter on the
engine or for additional fuel filtering performance beyond what
the factory filter offers.
1050345 High Flow Draw Straw Kit
This kit bypasses the stock fuel tank suction connection to
provide higher flow. The kit has a new top mount bulkhead fitting
with an extra-large diameter convoluted pickup tube for reduced
restriction. Draws fuel from the stock fuel pump basket.
1050330 High Flow Sump Kit
This kit installs in the bottom of the fuel tank to reduce restriction
on the supply line. Kit can be installed without dropping the tank.
Includes a screen to keep debris from entering the fuel line.
1050331 Flow-Max Monster 1/2in Line Kit
Replaces the stock 3/8” line with 1/2" all the way from the tank to
the engine. Includes fittings for the Flow-Max pump and the CP3
as well as fuel hose and clamps. Requires use of sump or draw
straw kit.
1050351 Flow-Max Water In Fuel Sensor
Relocates the stock WIF sensor from the fuel bowl on the engine
to the Flow-Max water separator. Includes extension harness
with built in resistor and new sensor that threads into bottom of
the new filter. Requires 1050340-WSP.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Tools Required for Installation
Required Tools
Knife to cut fuel hose
5/16”, 7/16”, 9/16” and 10mm sockets
Ratchet wrench
3/8” fuel line disconnect tool
Optional Tools
Tape Measure
Drill and 1/8” and 21/64” Bits
Pliers
90 degree pick tool
Installation
Disconnect both vehicle batteries for safety.
Raise the vehicle on a hoist, or support the vehicle with jack stands for safety.
Fuel Tank Modification
Note it is recommended to wait to begin installation when the fuel tank is almost empty
or to siphon the tank down to reduce the weight to make it easier to remove.
Note removing the rear driveshaft makes fuel
tank removal and future installation steps easier
but is not explicitly required.
Support the fuel tank with a transmission jack or
similar tool and remove the two fuel tank strap
nuts.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Loosen the fuel filler neck clamp and the clamp
on the vent tube. Slide the rubber hoses off the
rigid filler neck.
Locate the small fuel tank vent tube which runs
directly above the large filler neck. Follow this up
the filler neck to the small breather. Cut the wire
ties supporting this tube so that it can be removed
along with the fuel tank.
Unclip the DEF tank hose support and release
the hoses from the fuel tank.
Slightly lower the tank just enough to get your
hand on top to disconnect the fuel lines and
electrical connector. Do not let the tank hang by
the fuel hoses!

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Unplug the fuel pump module gray electrical
connector.
Disconnect the two fuel line quick connect fittings
from the top of the fuel pump module.
Slowly lower the tank being careful to ensure the
tank is not hooked on any wiring or hoses.
Transfer the tank from the jack to a suitable work
surface.
Before opening the tank up, thoroughly clean the
area around the fuel pump module. Blow off with
air and scrape off any dirt, debris and rust
otherwise this will enter the fuel inside the tank.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Remove the lock ring from the fuel pump module
by tapping it on the tangs with a mallet and
screwdriver or suitable tools. Work around the
ring to move it evenly to make removal easier.
Lift the fuel pump module out of the fuel tank
being careful not to damage the fuel float arm or
sender unit. Pour excess fuel from the bowl back
into the tank.
Cut the larger of the two Teflon fuel pickup tubes
at the top of the fuel module. Use a utility knife to
create a slit in the tube. Cut the other end of the
flexible tube off at the “H” adapter. Leave the
other smaller tube in place and leave the return
line in place.
Cut off a short section of supplied black rubber
hose (1604053). Use one of the supplied hose
clamps (1505001) to attach the hose to the top of
the fuel module assembly.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Check the length of the rubber hose by putting it
in the fuel basket and compressing the fuel
module assembly to the approximate installed
height. The end of the rubber hose should be just
off the bottom of the basket. Now cut a V notch in
the bottom to ensure that if it contacts the bottom
of the fuel basket it won’t stop the flow of fuel.
Use a wire tie to hold the fuel hose in the basket
by gently tying it to the original fuel pump plastic
bracket. Do not make this tie too tight or it will
pinch the fuel line.
The fuel pump module assembly is now
configured with the feed line drawing directly from
the fuel basket, bypassing the factory fuel pump.
The return line portion should be left stock.
Ensure the fuel tank gasket is clean. Reinstall the
basket in the tank and reinstall the lock ring in the
reverse manner of removal. Note the fuel pump
module will only fit in the tank one direction due to
a locator tab.
Do not install fuel tank until wire harness is
installed.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
FlowMax Wiring Harness Installation
Locate the harness supplied in the kit (1500331).
Mount the relay socket in the engine bay near the top
of the firewall at the driver’s side. Zip tie it to the
existing engine bay wiring there. Alternatively you
may use a self-tapping screw to secure the relay
socket.
Unclip the windshield washer hose support from the
ground stud on the driver’s side of the engine bay.
Install the black ground wire from the BD harness
onto the ground terminal stud. Use the supplied M6
nut (FT-90700) to fasten the terminal. Reinstall the
windshield washer fluid hose support.
Open the fuse box lid and remove the large nut
securing the fuse box power feed. Install the battery
power wire (red or orange) from the BD harness on
the stud and reinstall the nut.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Feed the two remaining portions of the BD wiring
harness down the firewall to the driver’s side frame
rail. These will be run to the fuel tank and the new
FlowMax fuel pump.
The two pin gray plug will connect to the FlowMax fuel
pump in a later step. Leave this wire for now.
NOTE Picture illustrates FlowMax pump which is not
yet installed.
Route the longest section of harness along the frame
rail all the way back to the fuel tank. The 4 pin gray
plug will connect in line with the original fuel pump
connector. This will serve as a trigger for the new fuel
pump relay. This is easiest to install before the fuel
tank is reinstalled. Secure the wiring with tie wraps.
Now that the fuel pump module electrical connector has been installed, the tank may
be installed, or optionally left out until the end of the installation. Installation is the
reverse of removal.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
FlowMax Pump Mounting
This kit is supplied with self-threading bolts and
matching washers to allow for direct mounting to
the frame if desired. This is not the suggested
installation method for most vehicles. See bottom
of instructions for optional frame mounting or
continue reading for normal installation method.
Strap Mount vs. Direct Frame
Mount
Insert the three vibration isolators (1500356) into
the pump bracket (1500355). Install the three M8
bolts (1900015) with the three M8 washers
(1402609) and bolt to the frame mount bracket
(1500373).
Position the frame mount bracket on the outside
driver side of the frame and determine mounting
location. The suggested location is below the
driver’s door, just behind the front lower control
arm mounting point.
On the inboard side of the frame, pop out the
fuel/brake line retaining bracket and the wiring
harness clip. This will allow for installation of the
band straps.
Isolator
Pump Bracket
Washer

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Install the two band straps (1500392) around the
frame and ensure no wiring or other lines will get
pinched by the straps.
Orient the straps so that the threaded stud end is
on the top to make tightening easier.
Position the fuel pump bracket under the band
straps. Start the nuts by hand and tighten the
band straps until the bracket is snug. There is no
need to overtighten these straps, the nuts are
self-locking and will not back off.
Recommended torque 80-90 in-lbs.
Ensure straps rest nicely on the bracket.
Reinstall the fuel line retainer bracket and wiring
harness clip on the back side of the frame. Note
that the holes for this should not be covered by
the FlowMax mounting straps. If they are,
reposition the strap.
Install the two small band straps (1500358)
through the pump bracket as shown

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 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
Lift the pump into place and rotate so that the IN
is orientated to the rear of the truck and OUT is
towards the front of the truck.
Start the nuts on the band clamps.
Center the pump so that the clamps are both
holding the black section of the pump body then
tighten.
Recommended max torque 72 in-lb.
NOTE Clamping the pump too high or too low
may put strain on the motor and cause shaft
misalignment leading to premature wear or
increased motor loading.
Ensure both straps are secured to the black
motor body only.
If installing the optional filter kits, install these
now.
Refer to filter kit instructions for install of fittings.
Install the inlet (1500311-M) and outlet
(1500311) hose fittings into the pump (or pre /
post filters) by removing the plastic protective
caps and threading in the supplied fittings.
IMPORTANT The fitting with the screen is
installed to the IN port of the pump and functions
as a debris screen.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 15 -
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
Fuel Line Routing
Locate the stock fuel line disconnect at the frame
rail near the transmission bell housing. Position a
drain pan below to catch any spills. Remove the
metal retainer clip from the larger of the two lines
(3/8” diameter). This is the line that feeds the fuel
filter bowl.
Use a 3/8” fuel line disconnect tool to undo this
connection.
Insert the steel fuel line quick connect adapter
(1500418) into the end of the remaining fuel hose
(1604053). Install a hose clamp (1505001).
Feed the fuel hose over the frame rail from the
FlowMax pump to the fuel line just disconnected
to determine the required length and cut the hose
to length. (Approximately 26 inches).

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 16 -
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
Install a section of the supplied protective loom
(1330175) over the hose. This will help protect it
from abrasion.
Now install the hose assembly. Connect the quick
connect fuel line fitting and reinstall the original
metal clip over top.
Connect the other end to the FlowMax pump
using a hose clamp (1505001).
Install a wire tie around the hose on the bottom of
the body for support as shown.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 17 -
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
Locate the factory fuel line disconnect at the
stock rear fuel filter, located beside the fuel tank.
We want to disconnect the outlet from the filter as
this is where the FlowMax pump will draw fuel
from. This is the fitting towards the front of the
truck. Pull out the red locking using a pick or
similar tool.
Push in the release button on the top side of the
quick connect fitting to disconnect it from the filter
housing.
Fuel may drip out when disconnected, position a
drain pan below.
Install the supplied plastic 90 degree quick
connect fitting (1500419) into the end of the
remaining fuel hose (1604053) and install a
clamp (1505001).
Install the remaining split loom (1330175) over
the hose for protection.
The hose and loom will be trimmed to length
during the following installation steps.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 18 -
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
Connect the quick connect fitting to the outlet of
the fuel filter assembly. Fish the other end of the
hose over the top of the fuel tank, so that the
hose crosses the frame rail as shown in the
following pictures.
Support the hose with the two supplied P-clamps
(1462115) and install these to the two small studs
on the bottom of the cab using M6 washers
(1601522) and nyloc nuts (1130058) provided.
These studs will not exist on standard cab trucks,
instead zip tie the hose to secure it as required.
Add an additional wire tie to keep the hose away
from the parking brake cable on the mount tab on
the bottom of the body.
Now that the hose is routed correctly, trim it to
length to reach the FlowMax pump (approx. 85
inches). Trim back the split loom a couple of
inches to allow clamp installation.
Install the hose clamp (1505001).

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 19 -
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
Finally, plug in the FlowMax pump to the wiring
harness that was installed earlier.
Use a wire tie to hold the harness to the ground
strap wire on the frame.
All of the fuel line routing should be complete. Check the lines are adequately
supported. Ensure no fuel hose is exposed to possible chafing as that can rub through
the hose.
Installation should now be complete. Reconnect batteries, and test the pump for
operation. Upon key on, you should hear the pump running.
If the pump motor does not run or there is a pressure or supply issue, refer to the end
of the manual for troubleshooting.

10 January 2018 #1050312D 2013-17 Dodge FlowMax Lift Pump Kit (I-00424)- 20 -
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
Place fuel pump and bracket in
place to ensure ample clearance.
Then, use the fuel pump bracket
as a template and mark the
locations to be drilled.
Mark holes with center punch.
Drill pilot holes to 1/8”. Drill main
holes to 21/64”.
Insert the three rubber isolators
(1500356) into the support
bracket.
Place the large washers
(1500357) on the inside of the
bracket against the rubber
isolator.
Using an 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