(I-00390) 1050470 - Venom Dual Fuel Kit

16 October 2019 (1050470/71) Venom Dual Fuel Kit (I-00390) 1
DOWNLOAD THE LATEST

INSTALL MANUALS AT
www.bddiesel.com
2011-2018 FORD 6.7L POWERSTROKE

Installation Instructions
1050470 2011-2018 FORD SUPERDUTY

1050471 2011-2018 FORD SUPERDUTY W/O CP3
1050470-SB 2011 & 2012-’18 PULLEY CONVERSION KIT
(ALL 2011 OR 2012+ DUAL ALTERNATOR)
U
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
BD ENGINE BRAKE, INC.

Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
K I T C O N T E N T S :
Please check to make sure that you have all the parts listed in this kit before you start
the disassembly of your truck.
1050470 – Kit Contents

1500731 1500708
CP3 Bracket CP3 Drive Pulley

Qty: 1 Qty: 1
0445020037 1500716 1500719
Duramax CP3 Pump Quick Connect

HP Fuel Line
(Not included on 1050471) Adapter
Qty: 1 Qty: 1 Qty: 2
1500721 1500720 GATK081298
Quick Connect Fitting Quick Connect Retainer Serpentine Belt


1050470 – Kit Contents Cont.

DAY89094 1500725 1500715
Idler Pulley Shroud Bracket Bracket Standoff

1502040 1500723 1500727
HiFlow CP3 Feed Quick Connect Straight

Quick Connect 90Deg Fitting
Fitting Fitting
1500704 F00N200499 1500728
Fuel Rail Fitting CP3 Output Fitting CP3 Return Banjo Fitting


1500718 FT-0424777 FT-99604842
CP3 Plug O-Ring -8 ORB O-Ring

GEN-19639 1604054 1453934
Push Pin ½” Fuel Hose M8 x 45 Bolt

Qty: 2 Qty: 7ft Qty: 3
1601711 W701629-S437 1401556
M8 x 25 Socket Head Bolt Ford Bolt M8 Washer



1402609 FT-40388 FT-1190681
M8 x 24 Washer M18 Split Washer M8 Lock Nut

FT-MJ2740000ZP00 FT-11115722 1502015
M18 Jam Nut M8 x 16 Bolt Banjo Bolt

1502019 1452821
Seal Washer Gear Clamp

Qty: 2 Qty: 1


1500387 FT-0606434 1500722
Spring Clamp Loctite Threadlock CP3/CP4 Harness

**1050470-SB – Optional Kit Contents**

CC3Z-8553-C GAT36234
Smooth Fan Pulley Smooth Idler Pulley

Qty: 1 Qty: 2

Contents
1050470 – Kit Contents .................................................................................................... 2
1050470 – Kit Contents Cont. ........................................................................................... 3
**1050470-SB – Optional Kit Contents** ........................................................................... 6
SPECIAL REQUIRED TOOLS .......................................................................................... 7
OPTIONAL ACCESSORIES ............................................................................................. 7
INTRODUCTION .............................................................................................................. 8
KIT FIT NOTES ................................................................................................................ 8
PRE-INSTALLATION ........................................................................................................ 8
REMOVAL ........................................................................................................................ 9
INSTALLATION .............................................................................................................. 14
OPERATION INSTRUCTIONS ....................................................................................... 31
SPECIAL NOTES ........................................................................................................... 31
SPECIAL REQUIRED TOOLS
➢ 10mm 12point (Triple Square) bit

➢ Cooling Fan clutch removal tools (FORD wrenches 205-036 and 303-214)
➢ 19mm Crows foot wrench
OPTIONAL ACCESSORIES
1050470-SB - Single Sided Belt conversion for 2011 model year trucks,
and trucks originally equipped with dual alternators.

INTRODUCTION
When trying to increase power levels of diesel engines, the high pressure fuel pump
originally installed in the vehicle is found to be insufficient. Upgraded turbochargers can
supply the engine with more air than the high pressure fuel pump can supply for.
The BD Venom Dual Fuel Kit allows 6.7L Powerstroke owners to increase the high
pressure fueling capabilities of their engine, by adding a second high pressure fuel
pump. This kit mounts a Bosch CP3 to the engine, and increases the power potential of
upgraded turbocharges and other engine modifications.
KIT FIT NOTES
This kit requires the use of custom tuning for the operation of the
additional high-pressure fuel pump.
If factory intake manifold assembly is still in use, some

modification to cold air intake may be required for pump pulley
clearance.
2011 model year and all year dual alternator trucks will require
optional 1050470-SB kit for conversion from double sided
serpentine belt to single sided belt.
If equipped with dual alternators, aux alternator will need to be

removed, and a single-alternator water pump may be required.
Kit will not work with factory dual alternators.
PRE-INSTALLATION
Secure vehicle and chock wheels to prevent vehicle from rolling. Record radio settings
then disconnect the negative terminals on both of the vehicle’s batteries, and then
disconnect the positive terminals.
For additional technical information, refer to Ford Technical Information or other shop
repair manuals (Mitchell, Alldata, etc…)

REMOVAL
VEHICLE SHOULD BE SAFELY SECURED BEFORE
INSTALLATION.
1. Remove intake tube assembly, and
associated parts. (Also referred to as
the air cleaner outlet pipe).
Note: Refer to shop manual for

additional removal details if required.
2. Using a 13mm socket, remove fan

stator nuts and pull stator away from
engine, to allow access to the
cooling fan clutch.
3. Unplug cooling fan connector, and

unbolt bracket from engine using a
13mm socket.

4. Remove cooling fan from pulley hub.
Carefully lay fan against radiator
inside fan shroud housing.
Note: Removal may require the use

of special fan clutch removal
wrenches.
5. Using a 3/8in drive ratchet or

breaker bar, remove factory
serpentine belt by rotating tensioner
clockwise and pulling belt off.
6. Cut plastic ties, and using a 10mm

socket, remove plastic wiring loom(s)
located over the passenger side
valve cover.
Note: This wiring will be tucked

behind installed CP3 pump.

7. Un-plug OEM CP4 pump, and pull
wiring out toward front of engine for
access to connector.
8. Remove the grey plastic insert from

the OEM CP4 connector using a
small screw driver. This part will be
modified to fit the new CP3 to CP4
wiring harness.
9. Using a small file, remove the

keyways (ribs) on both sides of the
grey plastic insert. Then install back
into OEM CP4 connector.

10. Remove passenger side fan shroud
support stud, using a 30mm wrench.
11. Remove upper bolt from secondary

water pump, using 10mm socket.
12. Remove both idler pulleys using a

15mm socket. These will be
relocated to CP3 bracket, once
installed.
Note: If these pulleys are grooved,

they will be replaced with smooth
pulleys from the optional kit
1050475-SB, using OEM hardware.

13. Note: If originally equipped with a
single sided serpentine belt, skip to
step 16 of removal process.
If the truck was outfitted with a

double sided belt, and a grooved fan
drive pulley as shown to the right,
move onto the following removal
process steps to install optional
smooth fan pulley hub.
14. Using 13mm socket, remove fan

pulley hub from front of engine.
15. Using 13mm Socket, install smooth

fan pulley hub CC3Z-8553-C, found
in optional kit 1050470-SB. Torque
fasteners to 18 ft-lbs.
Leave upper three (3) bolts loose for
installation of CP3 bracket assembly.

16. Using 13mm socket, remove three
(3) upper bolts from fan pulley hub to
allow the CP3 bracket to be
installed.
INSTALLATION
17. This kit was designed for use with a
LBZ/LMM style cp3 pump.
Note: Fuel injection equipment is

manufactured to very precise
tolerances and fine clearances. To
prevent fuel system damage, it is
essential that absolute cleanliness is
observed when working with these
components.
18. Using 17mm socket, remove OEM

output fitting (seen here in black)
from port. In its place, install plug
1500718 using a 17mm socket.
Torque plug to 74 ft-lbs.

19. Remove OEM plug located adjacent
to the output fitting using T50 Torx
bit.
Note: Use care not to lose the ball

bearing and spring found inside this
port!
20. Carefully remove spring from OEM

plug and install onto new output
fitting F00N200499.
21. Install new output fitting with spring

and ball bearing. Torque to 56 ft-lbs,
using a 17mm socket.
Note: Ensure ball bearing is installed

into port before installing fitting!

22. Mount CP3 pump to CP3 bracket
1500714. Use three(3) supplied
1453934 Bolts, six(6) 1401556
Washers, and three(3) FT-1190681
Nuts. Torque fasteners to 20 ft-lbs
using a 13mm socket, and 13mm
wrench.
23. Install supplied idler pulley

DAY89094, followed by 1402609
Washer, then the FT-11115722 Bolt.
Using a 13mm socket, torque
fastener to 20 ft-lbs.
24. Install bracket and pump assembly

onto the front of the engine. Using
the OEM bolts from the cooling fan
pulley hub. Using a 13mm socket,
snug the bolts hand tight at this point.
Note: The wiring running along the

coolant passage behind the pump
may need to be pushed back to allow
space.

25. Insert stand-off 1500715 between
CP3 bracket and engine, using the
supplied longer OEM bolt W701629-
S437.
26. Torque all bolts from bracket to

engine to 18 ft-lbs, using a 13mm
socket. Excluding lower right hand
bolt (see arrow). This bolt will be
installed with the cooling fan
assembly later.
27. Install OEM idler pulleys as shown

using OEM hardware. Using a 15mm
socket, torque fasteners to 35 ft-lbs.
Note: If equipped from factory with

grooved idler pulleys, use smooth
pulleys from optional kit 1050470-SB,
and install with OEM hardware.

28. Install CP3 drive pulley
1500708 onto pump shaft with
washer FT-40388 and jam nut FT-
MJ2740000ZP00. Using a 27mm
socket, torque nut to 75 ft-lbs.
Note: It may be easier to apply final

torque to nut after serpentine belt has
been installed.
29. Ensure all pulleys are free running

and have clearance. If interference
exists, it may help to loosen bolts on
main bracket and adjust position on
engine.
30. Locate passenger side fuel rail,

located above valve cover. Remove
small plug located at the front of the
rail using a 10mm 12 point bit (also
known as a triple square).
Note: Clean area thoroughly before

removing plug. Fuel injection
equipment is manufactured to very
precise tolerances and fine
clearances. To prevent fuel system
damage, it is essential that absolute
cleanliness is observed.

31. Install supplied fuel rail fitting
1500704, into previously plugged port
(front end of passenger side fuel rail).
Using a 22mm socket, torque to 75 ft-
lbs.
32. Install supplied fuel line 1500716

between the installed fuel rail fitting,
and the CP3 output fitting. Torque
both ends to 30 ft-lbs using 19mm
crows foot wrench.
Note: Ensure both ends of the fuel

line are seated before applying final
torque. To perfectly align both ends
of fuel line, a small amount of
bending adjustment may be required.
33. Route OEM CP4 pump wiring behind

installed CP3 pump as shown.

34. Plug-in supplied wiring harness
1500722 into OEM CP4 connector,
and CP3 as shown.
35. Loop supplied harness around

toward OEM CP4 pump, and pull
underneath coolant crossover
passage. Plug harness into OEM
CP4 pump.
36. Route harness and wiring behind

CP3 pump, and ensure wiring is not
directly contacting exhaust manifolds,
or any other hot surface.

37. Remove the OEM CP3 inlet fitting
and transfer the sealing washer over
to the new 1502040 HiFlow fitting as
shown.
38. Install 1502040 HiFlow pressure feed

fitting sealing washer, and torque to 6
ft-lbs.
Note: High flow fitting has a thin wall

and may fracture if over-torqued. Do
not exceed specified torque values!
39. Install 1500728 Banjo fitting,

1502015 Banjo bolt, and 1502019
seal washers. Assemble hand tight
as shown.
Note: Fitting will be tightened and

positioned when hose is installed.

40. Install supplied serpentine belt
GATK081298. Route as shown in the
accompanying image. Install is
reverse of removal.
41. Before installing cooling fan

assembly it may be helpful to adjust
OEM fan connector bracket by
bending the metal tab slightly forward
as shown. This is done to
accommodate the installed CP3
bracket thickness.
42. Re-install OEM fan connector bracket

to fan clutch.

43. Re-install cooling fan, and torque to
98 ft-lbs (May require use of fan
clutch wrench).
Note: It’s helpful to have fan

connector bracket bolt inserted into
its respective hole, while installing
cooling fan.
44. Torque fan bracket bolt to 18 ft-lbs,

using a 13mm socket and reconnect
fan clutch connector.
Note: Ensure fan brackets and

connector do not interfere with
serpentine belt or pulleys. There
should be at least a fingers width
clearance.
45. Re-install fan stator using three(3) of

the OEM fasteners, as shown. Using
a 13mm socket, torque to 12.5 ft-lbs
(150 in-lbs).
Skipping upper passenger side
mount.

46. Using 1601711 fastener, temporarily
install supplied 1500725 stator
support bracket onto the passenger
side upper stator mount.
This replaces support for upper
passenger side.
Mark fan stator through holes on

1500725 bracket, and then remove
for drilling holes.
47. Drill two(2) 6mm(.236in) diameter

holes on marks made in previous
step.
Note: It is helpful to use a step drill

bit for drilling plastic stator.

48. Re-install the 1500725 bracket using
supplied 1601711 fastener, and
two(2) GEN-19639 push pins on the
fan stator.
Torque fastener to 15 ft-lbs using
6mm hex drive.
49. Note: Some clearance of fan stator

may be required for pulley clearance.
This can be done with a Dremel, or
small saw.
50. Assemble an FT-0424777 O-ring

onto each 1500721 ORB adapter as
shown.
Note: Use care not to cut or damage

O-ring!
51. Insert two(2) FT-99604842 O-rings

into each 1500719 quick-disconnect
adapter. They are installed into the
internal O-ring grooves inside the
large end.
Note: Can be helpful to use a small

flat blade screwdriver.

52. Install a 1500721 ORB adapter with
O-ring into each 1500719 quick-
disconnect adapter as shown. Torque
to 15 ft-lbs, using 7/8in wrench.
Note: Apply FT-0606434 Loctite to

threads
Using 4-1/2 in of supplied ½in hose,

use 1452821 gear clamps to secure
a 1500727 quick-disconnect fitting in
each end as shown.
Remove OEM fuel tube assembly, by

pinching tabs together on quick-
disconnects, and pulling up on
colored collars.

53. Install a pre-assembled quick-
disconnect adapter (arrow 2) onto
OEM fuel filter outlet, in place of fuel
tube assembly.
Apply FT-0606434 Loctite to
1500720 retaining collar (arrow 1),
and slide over outlet, behind
shoulder, and thread into adapter.
Torque to 10 ft-lbs. 1
2
54. Note: It’s helpful to put a small
amount of diesel fuel onto o-rings,
and/or fuel filter outlet to assist
assembly.
55. Install new pre-assembled fuel tube
between quick-disconnect adapter,
and fuel pump feed inlet.
56. Note: A small amount of diesel fuel

on o-rings can help install here as
well.
57. Locate OEM fuel return quick-

disconnect (seen here with blue
latch), and remove.
This is done by lifting the locking
collar and depressing tab while
pulling up.

58. Install second quick-disconnect
adapter onto return outlet (arrow 2).
Apply FT-0606434 Loctite to
1500720 retaining collar (arrow 1), 2
and slide over outlet, behind
shoulder, and thread into adapter.
Torque to 10 ft-lbs.
1
Plug OEM fuel return line onto quick-

disconnect adapter as shown, and
depress locking collar.
Insert 1500723 quick-disconnect

fitting into end of supplied 1/2in fuel
hose, and secure with 1452821 gear
clamp.

59. Connect hose to quick-disconnect
adapter located on fuel filter, and
route fuel tube towards CP3 pump
feed fitting.
60. Trim to length and push hose over

feed fitting on CP3 pump. Secure
with 1452821 gear clamp.
61. Note: Ensure fuel hose is clear of

moving parts, or hot engine
components.
62. Insert 1500727 quick-disconnect

fitting into end remaining supplied
1/2in fuel hose, and secure with
1500387 spring clamp.

Connect hose to quick-disconnect
adapter with OEM return line, and
route fuel tube towards CP3 pump
return banjo fitting.
63. Trim fuel tube to length, and secure

with 1500387 spring clamp.
Tighten banjo bolt to 18 ft-lbs using
3/4in socket.
64. Note: Clock banjo fitting to ensure

return hose does not contact any
moving or hot engine parts.
65. Re-install intake tube, and any other

components removed for install of
pump.
66. Note: Double check fasteners and

fittings to ensure all joints and
connections are tight.

67. Prime fuel system several times using the filter pump, or lift pump and start
engine. Check for leaks.
OPERATION INSTRUCTIONS
Once all parts are installed, the vehicle will require custom tuning to operate both high
pressure fuel pumps together.
SPECIAL NOTES
When adding a second high pressure injection pump, the demand for fuel flow from the
factory lift pump will increase. Elevated horsepower levels may require an upgraded lift
pump to support the additional CP3 fuel requirements.
If you have any technical difficulties, concerns, comments, or complaints, please

phone our Technical Support hotline at (800) 887-5030 between 8:30am-5:00pm
PST (Pacific Standard Time) Monday to Friday.


(I-00390) 1050470 - Venom Dual Fuel Kit

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16 October 2019 (1050470/71) Venom Dual Fuel Kit (I-00390) 1

DOWNLOAD THE LATEST

2011-2018 FORD 6.7L POWERSTROKE

1050470 2011-2018 FORD SUPERDUTY

PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION

BD ENGINE BRAKE, INC.

1050470 – Kit Contents

CP3 Bracket CP3 Drive Pulley

Duramax CP3 Pump Quick Connect

Quick Connect Fitting Quick Connect Retainer Serpentine Belt

BD ENGINE BRAKE, INC.

1050470 – Kit Contents Cont.

Idler Pulley Shroud Bracket Bracket Standoff

HiFlow CP3 Feed Quick Connect Straight

BD ENGINE BRAKE, INC.

1050470 – Kit Contents Cont.

CP3 Plug O-Ring -8 ORB O-Ring

Push Pin ½” Fuel Hose M8 x 45 Bolt

M8 x 25 Socket Head Bolt Ford Bolt M8 Washer

BD ENGINE BRAKE, INC.

1050470 – Kit Contents Cont.

M8 x 24 Washer M18 Split Washer M8 Lock Nut

M18 Jam Nut M8 x 16 Bolt Banjo Bolt

Seal Washer Gear Clamp

BD ENGINE BRAKE, INC.

1050470 – Kit Contents Cont.

Spring Clamp Loctite Threadlock CP3/CP4 Harness

**1050470-SB – Optional Kit Contents**

Smooth Fan Pulley Smooth Idler Pulley

BD ENGINE BRAKE, INC.

SPECIAL REQUIRED TOOLS

➢ 10mm 12point (Triple Square) bit

BD ENGINE BRAKE, INC.

KIT FIT NOTES

If factory intake manifold assembly is still in use, some

If equipped with dual alternators, aux alternator will need to be

BD ENGINE BRAKE, INC.

Note: Refer to shop manual for

2. Using a 13mm socket, remove fan

3. Unplug cooling fan connector, and

BD ENGINE BRAKE, INC.

Note: Removal may require the use

5. Using a 3/8in drive ratchet or

6. Cut plastic ties, and using a 10mm

Note: This wiring will be tucked

BD ENGINE BRAKE, INC.

8. Remove the grey plastic insert from

9. Using a small file, remove the

BD ENGINE BRAKE, INC.

11. Remove upper bolt from secondary

12. Remove both idler pulleys using a

Note: If these pulleys are grooved,

BD ENGINE BRAKE, INC.

If the truck was outfitted with a

14. Using 13mm socket, remove fan

15. Using 13mm Socket, install smooth

BD ENGINE BRAKE, INC.

Note: Fuel injection equipment is

18. Using 17mm socket, remove OEM

1050470-SB – Optional Kit Contents