BD Diesel Performance FlowMAX Lift Pump V3 Installation Instructions Manual Download

Page: 2 / 14

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: 604-853-6096 | Fax: 604-853-8749 | 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: 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

8” Fuel Hose

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

Summary of Contents for FlowMAX Lift Pump V3

Page 1: ...Address P O Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 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 M...

Page 2: ...ts 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...

Page 3: ...e 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...

Page 4: ...t 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...

Page 5: ...ww 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 Tor...

Page 6: ...ill 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...

Page 7: ...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 ...

Page 8: ... 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 ...

Page 9: ...St Sumas WA 98295 U S Mailing Address P O Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 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 Washe...

Page 10: ... 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 604 853 6096 Fax 604 853 8749 Internet www bd power com 1998 5 1999 Trucks Only 2000 2002 Trucks Only ...

Page 11: ...er 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 fitti...

Page 12: ...ailing Address P O Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 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 ...

Page 13: ...he 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 1...

Page 14: ... S Shipping Address 88 446 Harrison St Sumas WA 98295 U S Mailing Address P O Box 231 Sumas WA 98295 Phone 604 853 6096 Fax 604 853 8749 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 ...

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