BD Remote Filter Kit

BD Remote Filter Kit
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
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2003-04½ DODGE CUMMINS
BD FlowMax LIFT PUMP KIT
Installation Instructions
P/N#
1050305
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.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
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Kit Contents:
1500300
1100111
1230116
1300131
FlowMAX Lift Pump
Qty: 1
¼” Flat Washer
Qty: 8
Lock Nut
Qty: 4
Tie Wrap (Medium)
Qty: 8
1300221
1330149
1500311
FlowMAX Anti-Vibration Mount
Hose Clamp
Qty: 7
-AN 8 ORB x 3/8” Barb
Qty: 2
Qty: 4
1604110
1502028
1500340
Elbow Fitting ¼” NPT – 3/8” barb
Qty:1
OEM Lift Pump Adapter
Qty: 1
3/8” Fuel Strainer
Qty: 1
1500310-B
1502029
1502021
1300529
FlowMAX Lift Pump Wiring Harness
Qty: 1
O-Ring
Qty: 1
3/8 Fuel Hose
Self Tap
Qty: 1
Qty: 78
1500325
1500314
1030104
FlowMax Mounting Bracket
Qty: 1
#10 Plated Washer
10/32” Nylock Nut
Qty: 4
Qty: 4
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
Optional Accessories:



1081130 - Low Fuel Pressure LED Alarm kit
1085220 – X-Monitor Digital Gauge Package (2003-07)
1080156 – Fuel Pressure Kit (X-Monitor Accessory)
Required Tools:









5mm Allen wrench
Drill
1/8” and 13/64” Drill bits
1/4” UNC Tap
Pliers
3/16” Flat Screwdriver
10 mm Socket or wrench
Small Pipe Cutter
Knife To Cut Fuel Hose
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
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7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
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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 fuel line extension hose to the brass
barb fuel fitting. Make sure that by re-routing
the hose it doesn’t rub on anything. Allow the hose to hang during pump installation (optional:
pinch the hose with some vise grips or clamps of some sort to prevent fuel leakage).
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
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Pump Installation
9.
From underneath the vehicle, locate the cross member and skid plate underneath the transfer
case. Remove the cross member/skid plate. There should be a total of 6 nuts/bolts to
remove.
Remove cross member and skid plate.
10. Once remove locate a clean
installation point on the inside
of the driver’s side frame rail.
11. Use the supplied mounting
bracket as a template to mark
the mounting holes. Select a
high enough location so when
the pump is mounted it will not
contact the cross member.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
12. Drill the marked holes and
taped to ¼ UNC (drill bit #7 or
13/64”) for mounting the rubber
isolators.
It is highly recommend that you
center punch the center of your
hole markings.
13. Install the 4 supplied rubber
isolators (P/N# 1300221).
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
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7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
14. Mount the mounting bracket
(P/N# 1500325) to the rubber
isolators. Use the supplied ¼”
flat washers (P/N# 1100111)
and
Nylock
nuts
(P/N#
1230116) to secure the bracket
to the isolators.
15. Before mounting mount, screw
in the ORB to Barb fittings in
both the inlet and outlet of the
pump. Do not over tighten, it is
an o-ring seal, not NPT.
16. Mount the FlowMax pump to
the bracket. Use the provided
#10-32 flat washers (P/N#
1500314) and Nylock nuts
(P/N# 1030104) to secure the
pump.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
-7-
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
17. With the pump mounted, cut
the hard fuel line about 12”
ahead of the pump. The fuel
supply line is the thickest of all
three lines.
You don’t have to use a tube
cutter as you will be removing
the section of hard line.
18. Route the fuel line that you
connected from the front of the
vehicle to the outlet of the
pump. Use a hose clamp to
secure this connection. Trim to
fit, the remainder of the hose
will be used for the inlet of the
pump.
19. 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,
then the fuel strainer. Finally
connect the outlet of the fuel
strainer to the inlet of the
pump.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
-8-
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
20. Secure each connection with a
hose clamp. Use two hose
clamps when securing the
rubber hose to the hard line.
21. 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.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
-9-
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
- 10 -
22. 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.
23. Make certain that all fuel lines, wiring harness’ are fixed in place well.
24. Lower the vehicle and re-install the battery cables.
25. Take the truck for a test drive and measure pump output pressures. The pump pressure sure
idle at 15-18psi.
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.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
7 April 2009
2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305
- 11 -
Trouble Shooting
Wiring harness diagram
If you have problems, complete the following tests or procedures,






Clean and re-tighten battery terminals.
Ensure there are no crimped/pinched sections of fuel line.
Change Fuel Filter
Check OEM connection to weather pack plug for 12V.
Check that fuse in supplied harness near battery terminal is not blown.
Check that all plugs are securely clipped together
The pump should operate between 16 and 18psi with 14V at idle. If you have lower voltage, then the pump
pressure will also be lower.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
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
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