7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-1 - 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.
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-2 - Kit Contents: 1500300 1100111 1230116 1300131 FlowMAX Lift Pump ¼ Flat Washer Lock Nut Tie Wrap (Medium) Qty: 1 Qty: 8 Qty: 4 Qty: 8 1300221 1330149 1500311 FlowMAX Anti-Vibration Mount Hose Clamp -AN 8 ORB x 3/8 Barb Qty: 4 Qty: 7 Qty: 2 1604110 1502028 1500340 Elbow Fitting ¼ NPT 3/8 barb OEM Lift Pump Adapter 3/8 Fuel Strainer Qty:1 Qty: 1 Qty: 1 1500310-B 1502029 1502021 1300529 FlowMAX Lift Pump Wiring Harness O-Ring 3/8 Fuel Hose Self Tap Qty: 1 Qty: 1 Qty: 78 Qty: 1 1500325 1500314 1030104 FlowMax Mounting Bracket #10 Plated Washer 10/32 Nylock Nut Qty: 1 Qty: 4 Qty: 4
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-3 - 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
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-4 - 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).
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-5 - 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.
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-6 - 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).
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-7 - 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.
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-8 - 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.
7 April 2009 2003-04½ Dodge Cummins FlowMAX Lift Pump Kit # 1050305-9 - 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.
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.
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.