BD Diesel Performance Flow-MAX V3 Installation Instructions 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

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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