Dodge 1998-99 24V Lift Pump OEM Bypass
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
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1998-02 DODGE CUMMINS 24V ISB
FLOWMAX LIFT PUMP KIT
Installation Instructions
Part# 1050301B
PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
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Kit Contents
1500350-L-REV-A
1500357
1500359
1500355
FLOWMAX Lift Pump
Qty: 1
Flat Washer
Qty: 3
Self Threading Bolt
Pump Bracket
Qty: 1
Qty: 3
1500356
1300529
1505001
1500311
FlowMAX AntiVibration Mount
Self Tapping
Screw
Hose Clamp
-AN 8 ORB x 3/8” Barb
Qty: 3
Qty: 1
Qty: 7
Qty: 2
1500310
1502033
1502021
FlowMAX Lift Pump Wiring Harness
Qty: 1
M12 x -8 JICM Adapter
Qty: 1
3/8” Fuel Hose
Qty: 78”
1502034
1500361
1500358
1500340
-8 JICF x 3/8” 90° ADAPTER
Qty:1
Drill Jig
T-Bolt Clamp
3/8 Fuel Strainer
Qty: 1
Qty: 2
Qty: 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: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
-3-
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
 1085210 – X-Monitor Digital Gauge Package
 1080156 – Fuel Pressure Kit (X-Monitor Accessory)
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.
Pump Installation
Locate a spot on the driver’s side frame rail near the front of the vehicle so that
there is room to use a drill. Tape the drill template in place. Ensure there is
ample room and nothing will contact the pump it this location.
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
1998-2002
Fuel supply
line is
largest line
Good
mounting
location
1. Center punch the three
holes, remove drill template
and drill a pilot hole to 1/8”.
Then re-drill to 11/32”.
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
-4-
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
2. 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.
Using a air ratchet (9/16”
socket) tighten the self
threading 3/8” bolt 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.
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
-5-
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
3. Locate the two supplied T
Bolt band clamps; unthread
the nut (7/16” Socket) from
each of them. Spread the
clamps apart and insert them
through 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.
4. Insert the ORB-Barb fittings
to the inlet and outlet of the
pump. Do not over tighten
as they use an Oring for
sealing.
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
-6-
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
-7-
5. Install the rubber hose to the inlet (IN) side of the pump with the use of one
hose clamp and run the line about 5” towards the rear for the vehicle. Cut the
hose at the 5”-6” length. Install supplied inline strainer with a hose clamp on
each end. Continue to route the supplied fuel towards the rear of the vehicle
over the skid plate. Locate a nice spot and cut the fuel supply line with respect
to stock fuel line clamp and skid plate. Be sure to use a tube cutter.
**CAUTION** Diesel fuel will spill out of line when cut.
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
-8-
1502033
1502034
Washer
6. 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.
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
1998-1999 Trucks Only
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
-9-
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
- 10 -
2000-2002 Trucks Only
7. Thread the JICM adapter (1502033) into the fuel filter bowl and tighten first. Do
not over-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 fitting, making sure to run the line to
the outlet (OUT) side of the pump. Remove the excess fuel line prior to installing
on outlet and clamping.
1998-99
2000-02
Top of filter housing
Rear of filter housing
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
- 11 -
Fuel Bowl Fitting
8. 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: 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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
- 12 -
9. 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.
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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
10.
Make sure that all fuel lines, wiring harness’ are fixed in place well.
11.
Re-install the front driveshaft (4x4 models only).
12.
Lower the vehicle, and re-install the battery cables.
- 13 -
The pump will develop 15-18psi at idle with 14VDC. If your battery voltage is
lower so will the pressure.
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: 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
24 November 2011
1998-2002 Dodge Cummins FlowMAX Lift Pump Kit # 1050301B
- 14 -
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 that you have at least 12 volts at the electrical connector at the pump.
Check that fuse in supplied harness near battery terminal is not blown.
Check that all plugs are securely clipped together
Run a hose from a fuel can full of diesel to the pump inlet to see if the
pressure changes.
If the pressure increases the problem is a restriction in the line possibly a
clogged fuel screen.
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: 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
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