BD Diesel Performance FlowMAX Lift Pump V3 Installation Instructions 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

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W

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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.