Installation Video

Duramax 3.0L 2020-Present Installation Video

Use the installation video along with this written guide. The installation video should be reviewed before beginning the pressure-port installation.

Installation Overview

Installation Note: Some customers find the oil pressure tee fitting difficult to install because of the limited access at the factory oil pressure switch/sensor location. To make installation easier, Insane Diesel offers an optional oil filter sandwich plate and thread extension kit that can cut installation time in half. The sandwich plate kit is available on our website: 3.0L Duramax Sandwich Plate & Thread Extension Kit.

Do not open labeled parts bags until instructed. Keep all labeled parts bags until installation is complete.

Before You Begin

• Verify all supplied kit components are present before beginning installation.
• Identify whether the kit uses the Under-the-Hood Bracket or Standard Bracket.
• Identify whether the pressure connection will use the standard factory oil pressure switch/sensor tee-fitting system or the optional oil filter sandwich plate with pressure port.
• Verify the supplied oil pressure port fitting, sealing washer, O-rings, oil return fitting, hose, filter housing, mounting bracket, and mounting hardware are correct for the selected configuration.
• Verify the bypass filter housing contains the filter element, lid O-ring, lid bolt washer O-ring, and all required sealing components.
• Read the entire installation guide before beginning.
• Review the installation video and reference photos before beginning.
• Park the vehicle on a level surface.
• Allow the engine to cool before servicing oil-system components.

Recommended Maintenance

Insane Diesel recommends installing your bypass oil filtration system during a scheduled engine oil and filter change whenever practical. Starting with fresh engine oil and a new full-flow oil filter helps maximize the performance and service life of your bypass filtration system.

For maximum engine protection, Insane Diesel recommends Lorenzo's Oil premium engine oil and Lorenzo's Oil Fuel Additive as part of your regular maintenance routine.

Required Tools

• Basic mechanic tool set.
• Inch-pound torque wrench.
• Foot-pound torque wrench.
• Crow's foot wrenches.
• Tools suitable for accessing and removing the factory oil pressure switch/sensor at a difficult angle when using the tee-fitting pressure-port option.
• Hose cutting tool or equivalent.
• Drill and drill bits appropriate for the selected mounting method, where required.
• Center punch, where drilling is required.
• Rivnuts and an appropriate rivnut installation tool for the Under-the-Hood Bracket installation. Rivnuts are not supplied with the kit.
• High-quality thread sealant for verified NPT fittings.
• Blue medium-strength threadlocker, such as Loctite 242 or equivalent, for mounting hardware where applicable.
• Zip ties or clamps for hose routing and securing.

Advanced Installation Notice

The standard tee-fitting installation requires proper tools, including crow's foot wrenches, to remove and install components at a difficult angle. Inspect the factory oil pressure switch/sensor location before beginning installation and plan for adequate access.

Important: Metric straight-thread fittings are tightened to 60 in-lbs unless a different verified torque is specifically listed for that component. Do not overtighten aluminum fittings.

Choose Your Installation Path

Before cutting hose or mounting the filter housing, mock up the selected mounting location, confirm service access, and verify the pressure and return hoses can be routed without kinking, stretching, or contacting hot, sharp, or moving components.

Kit Contents

Parts Gallery

Do not open labeled parts bags until instructed. Keep all labeled parts bags until installation is complete.

Match each labeled part number to the image below. The black HX1SHBK housing is shown as the gallery reference; blue and red housing color options, the D12 sealing washer, and the ODU filler-cap O-ring are intentionally not shown.

NOTE: Fittings that use tapered NPT threads are not designed to thread completely into the component. Apply the specified thread sealant and tighten the fitting to the specified torque. Some fitting threads may remain visible after installation; this is normal.

Important Torque Note: Follow the verified torque specification and sealing method for each fitting. The female hose socket-to-fitting-barb assembly does not use a torque specification. Tighten the fitting barb until it meets the hose socket.

Installation Procedure

Follow the steps below in this order. First identify the filter housing location, pressure location, pressure-port configuration, and return location. Measure and build the hoses before final assembly. Prepare the mounting bracket, assemble the filter housing, install the hoses on the housing, mount the completed housing, route the hoses, and then complete the engine-side pressure and return connections.

1. Find the Filter Housing Location

Identify the final filter housing location before cutting hose or installing the bracket. If your kit uses the Under-the-Hood Bracket, use IFS_90UO. If your kit uses the Standard Bracket, use ZBRCKX12.

• Verify the housing location provides adequate structure for the mounting bracket and filter housing.
• Verify the pressure and return hoses can reach their connection points using the supplied hose.
• Verify adequate clearance for the filter housing, hose routing, hood closure where applicable, and future filter service.
• Verify clearance from wiring, suspension and steering components where applicable, driveline components, exhaust components, sharp edges, moving parts, and excessive heat sources.
• Confirm the filter housing lid can be removed for future service.
• Before drilling, inspect both sides of the selected mounting surface to ensure no vehicle components will be damaged.

2. Find the Pressure Location

If using the standard tee-fitting pressure-port option, watch the installation video to locate the factory oil pressure switch/sensor and verify access before continuing. This installation may require crow's foot wrenches because of the limited working angle.

Optional Pressure-Port Note: The optional 3.0L Duramax Sandwich Plate & Thread Extension Kit provides an oil filter sandwich plate with a pressure port and may be used instead of the standard factory oil pressure switch/sensor tee-fitting location.

3. Find the Return Location

The return line connects to the supplied FLLCDUO oil filler cap using the ODU O-ring and AN06-02MS90 return fitting. Verify the oil filler cap location and planned return-hose path before cutting the hose.

4. Measure and Build the Hoses

Before proceeding with Step 4, watch The Complete Insane Diesel Hose & Fitting Installation Guide below so you are familiar with the correct reusable hose fitting assembly procedure.

The kit includes 9 ft of LW06BK continuous hose. For the Under-the-Hood Bracket option, approximately 4 ft 6 in for the pressure hose and 4 ft 6 in for the return hose may be used as reference lengths. For the Standard Bracket option, measure and cut both hoses based on the final routing. Verify the complete pressure and return routing before making either cut.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

The Complete Insane Diesel Hose & Fitting Installation Guide

1. Determine the complete routing between the planned filter housing location, pressure source, and return.
2. Starting at one end, route the hose from the planned filter housing location to the pressure source and mark the pressure-hose cut location.
3. Starting from the opposite end, route the hose from the planned filter housing location to the return and mark the return-hose cut location.
4. Verify the cut marks do not overlap. If hose remains between the marks, cut between the marks so both can remain slightly longer.
5. Follow a safe and serviceable routing path.
6. Avoid moving components, steering and suspension components, sharp edges, rotating assemblies, exhaust components, and excessive heat sources.
7. Leave sufficient slack for normal engine and chassis movement.
8. Verify the complete routing before cutting the hose.
9. Cut the hose at the verified cut locations.
10. Cut each hose squarely and cleanly. Ensure each cut is free from frayed braid, burrs, or deformation.
11. Remove the socket from the fitting assembly. Insert the hose into the fitting socket until the rubber can be seen touching the bottom of the female threads of the socket. Make sure ALL of the nylon braided covering is fully inside the socket, with no frays or nylon bunching.
12. Lubricate the fitting barb with clean oil and thread the barb into the fitting socket until the barb touches the socket. Ensure while threading the barb into the socket that it is not pushing the hose out of the socket.
13. Assemble the reusable hose ends as shown in The Complete Insane Diesel Hose & Fitting Installation Guide. The female hose socket-to-fitting-barb assembly does not use a torque specification. Tighten the fitting barb until it meets the hose socket.
14. Pressure Hose Assembly: Install one AN06-04MS90 fitting on the filter-housing end of the pressure hose. For the standard tee-fitting pressure-port configuration, install AN06-06FJ on the engine-side pressure end.
    AN06-04MS90 — Pressure Hose — AN06-06FJ
15. Return Hose Assembly: Install the remaining AN06-04MS90 fitting on the filter-housing end of the return hose and AN06-02MS90 on the oil-filler-cap return end.
    AN06-04MS90 — Return Hose — AN06-02MS90
16. Before moving on, verify the completed hose assemblies match the selected pressure-port configuration and are correctly identified.
17. After both hoses have been assembled, verify they are free from kinks and twists and are ready to be installed and routed in the following steps.

Important: Do not allow the hose to become twisted during installation. Verify each hose follows a smooth routing path with large-radius bends and does not place side loads on the fittings.

5. Prepare the Selected Mounting Bracket

1. If using IFS_90UO, position the Under-the-Hood Bracket at the verified mounting location and confirm adequate clearance for the complete bracket and filter housing assembly.
2. If using ZBRCKX12, position the Standard Bracket at the previously identified mounting location and verify the bracket, housing, and hoses can be installed without interference.
3. Inspect both sides of the mounting surface before drilling or installing mounting hardware.
4. Apply blue medium-strength threadlocker, such as Loctite 242 or equivalent, to bracket mounting hardware where applicable.
5. Install the selected bracket using the mounting hardware and procedure appropriate for the selected mounting location.
6. Verify the bracket is securely mounted and the filter housing will remain accessible for future service.

6. Assemble and Inspect the Filter Housing

1. Remove the filter housing lid bolt, washer, and lid from the filter housing.
2. Verify the bypass filter element is properly installed inside the filter housing with the metal ring facing up toward the lid.
3. Inspect the filter housing lid O-ring and verify it is properly installed and fully seated in the groove. Replace the O-ring if it is damaged or missing.
4. Inspect the lid bolt washer O-ring and verify it is properly installed and free from cuts, cracks, deformation, or other signs of damage. Replace the O-ring if necessary. Make sure the lid bolt washer chamfer faces toward the lid.
5. Press down firmly on the filter element to seat the lower O-ring. If the filter element is not centered in the housing, center the lid over the element, apply downward pressure, and move the lid and filter element together until the element is centered in the housing. Maintain downward pressure while installing the washer and lid bolt.
6. Tighten the filter housing lid bolt to 30 ft-lbs cold or 35 ft-lbs at operating temperature.

Do not operate the engine with a damaged, missing, or improperly installed O-ring.

7. Install the Hoses on the Filter Housing

1. Apply high-quality thread sealant to the 1/4 NPT threads of both AN06-04MS90 fittings already installed on the filter-housing ends of the completed hose assemblies.
2. Install the AN06-04MS90 from the pressure hose into the filter housing IN port and tighten the 1/4 NPT connection to 120 in-lbs.
3. Install the AN06-04MS90 from the return hose into the filter housing OUT port and tighten the 1/4 NPT connection to 120 in-lbs.
4. Verify the pressure hose is connected to IN and the return hose is connected to OUT.

AN06-04MS90 is a 1/4 NPT fitting and requires high-quality thread sealant. Do not apply thread sealant to AN flare connections, O-rings, sealing washers, straight-thread sealing connections, or other sealing surfaces.

NOTE: The fittings installed in the bottom of the filter housing use tapered NPT threads and are not designed to thread completely into the housing. After the fittings are tightened to the specified torque, some fitting threads may remain visible. This is normal.

8. Mount the Assembled Filter Housing

8A. Under-the-Hood Bracket — IFS_90UO

1. Loosely install the filter housing mounting bolts into the bottom threaded bosses of the filter housing so the IFS_90UO bracket can be positioned on the housing while still allowing the housing to slide and be adjusted.
2. Position the IFS_90UO bracket onto the loosely installed filter housing mounting bolts. Do not tighten the housing mounting bolts at this time.
3. Place the filter housing and bracket assembly into the intended Under-the-Hood mounting location.
4. Move the filter housing forward on the bracket until there is adequate clearance to remove the filter housing lid and filter element during future service.
5. Verify the housing is positioned correctly for lid removal, filter-element removal, hose routing, hood clearance, and surrounding vehicle-component clearance.
6. With the housing and bracket held in the final desired position, use the IFS_90UO bracket as a template to mark the mounting-hole locations on the inner body support.
7. Remove the filter housing and bracket assembly from the mounting area.
8. Inspect behind the inner body support before drilling to verify no vehicle components will be damaged.
9. Center-punch the marked mounting-hole locations.
10. Drill the mounting holes to the size required for the installer-supplied rivnuts.
11. Install the installer-supplied rivnuts into the drilled mounting holes using the appropriate rivnut installation tool and verify each rivnut is fully seated and secure.
12. Install the pressure-hose AN06-04MS90 fitting into the filter housing IN port and the return-hose AN06-04MS90 fitting into the filter housing OUT port as described in Step 7. Tighten each AN06-04MS90 fitting to 120 in-lbs.
13. Return the filter housing to the previously established service position on the IFS_90UO bracket and verify there is still adequate clearance to remove the lid and filter element.
14. Apply blue medium-strength threadlocker to the filter housing mounting bolt threads.
15. Tighten the filter housing bottom mounting bolts to 18 ft-lbs.
16. Begin routing the pressure and return hoses through the required openings in the fenders and inner body supports as the complete filter housing and IFS_90UO bracket assembly is moved into the mounting location.
17. Position the bracket over the installed rivnuts while continuing to guide the hoses through the openings without kinking, twisting, pinching, or placing tension on the fittings.
18. Install the bracket mounting bolts into the rivnuts and tighten them securely.
19. Verify the bracket and filter housing are secure, the hoses are not pinched or twisted, and the filter housing remains far enough forward for the lid and filter element to be removed during future service.

Important: Do not final-tighten the filter housing mounting bolts until the filter housing has been positioned far enough forward on the IFS_90UO bracket to allow the lid and filter element to be removed for service.

8B. Standard Bracket — ZBRCKX12

1. With the pressure and return hoses already installed on the filter housing, feed both hoses toward their previously identified engine connection points.
2. Position the completed filter housing onto the already-installed ZBRCKX12 Standard Bracket using the side mounting bosses on the filter housing.
3. Apply blue medium-strength threadlocker or equivalent to the filter housing mounting bolt threads.
4. Tighten the filter housing side mounting bolts to 35 ft-lbs.
5. Verify the filter housing is securely mounted and the housing lid can be removed for future service.

9. Route the Hoses

1. Route the pressure and return hoses along the paths established during the measurement step.
2. Verify both hoses are clear of exhaust components, steering and suspension components, driveline components, sharp edges, and excessive heat sources.
3. Verify there are no kinks, twists, or excessive tension in either hose.
4. Leave sufficient slack for normal engine and chassis movement without placing tension on the hose or fittings.

10. Install the Standard Tee-Fitting Pressure Connection and Connect the Pressure Hose

Standard Tee-Fitting Pressure-Port Option Only: Complete this step when using the factory oil pressure switch/sensor location. If the optional oil filter sandwich plate pressure-port configuration is being used, do not install the TM1275B tee at the factory sensor location.

Installation Note: Watch the Step 10 installation video before beginning this procedure. Access to the factory oil pressure and oil temperature sensors is limited, so review the sequence before removing either sensor.

Step 10 Tee-Fitting Installation Video

For installers who prefer the alternate pressure-port configuration, the optional 3.0L Duramax Sandwich Plate & Thread Extension Kit is available from Insane Diesel.

1. Disconnect the electrical connectors from both the factory oil pressure switch/sensor and the factory oil temperature sensor.
2. Remove the factory oil pressure switch/sensor from the engine.
3. Remove the factory oil temperature sensor from the engine oil temperature port location.
4. Apply high-quality thread sealant to the NPT threads of AN06-02MP90.
5. Install AN06-02MP90 into the center branch of the TM1275B tee fitting and tighten AN06-02MP90 to 110 in-lbs. As the fitting is torqued to specification, orient AN06-02MP90 so it is facing toward the factory oil pressure switch/sensor.
6. Verify the factory oil pressure switch/sensor sealing washer is present and installed correctly. Install the factory oil pressure switch/sensor into the remaining sensor port of TM1275B and tighten the factory oil pressure switch/sensor to 60 in-lbs. Do not apply NPT thread sealant to the sensor-to-TM1275B straight-thread connection.
7. Install the supplied D12 sealing washer onto the TM1275B tee fitting. Do not apply thread sealant to the D12 sealing washer.
8. Install the completed TM1275B tee fitting assembly into the factory oil pressure port. Use the swivel on the fitting as a ratcheting device to progressively thread the tee fitting all the way into the oil pressure port without forcing or cross-threading the connection.
9. Tighten the TM1275B tee fitting to 60 in-lbs. Do not apply NPT thread sealant to the TM1275B straight-thread / D12 sealing-washer connection.
10. Verify the factory oil temperature sensor sealing component is present and installed correctly, then reinstall the factory oil temperature sensor into its original engine oil temperature port location.
11. Reconnect the electrical connectors to both the factory oil pressure switch/sensor and the factory oil temperature sensor.
12. Connect the AN06-06FJ pressure-hose end to AN06-02MP90. Place a backup wrench directly on the hex of the installed AN06-02MP90 fitting and hold that fitting stationary while tightening AN06-06FJ.
13. Tighten AN06-06FJ to 60 in-lbs, loosen the fitting, then re-tighten to a final torque of 110 in-lbs.
14. Verify the pressure hose and completed tee-fitting assembly have adequate clearance from nearby engine components, exhaust components, sharp edges, and excessive heat sources.

Important Access Note: The exhaust mounting bracket may need to be partially disassembled to provide enough clearance for the tee-fitting installation. Reassemble the exhaust mounting bracket after the completed tee assembly and both sensors are installed, and verify all removed hardware is properly reinstalled and secured before startup.

Thread Sealant: AN06-02MP90 is an NPT fitting and requires high-quality thread sealant. Do not apply thread sealant to the D12 sealing washer, TM1275B straight-thread connection, factory oil pressure switch/sensor-to-TM1275B straight-thread connection, AN06-06FJ AN flare connection, O-rings, or other sealing surfaces.

11. Install the Oil Filler Cap Return Fitting and Connect the Return Hose

1. Inspect the supplied FLLCDUO oil filler cap and verify the ODU O-ring is properly installed and fully seated in the O-ring groove.
2. Inspect the O-ring for cuts, cracks, deformation, or other signs of damage. Replace it if damaged or missing.
3. Apply a thin coat of clean engine oil to the O-ring and to the inside of the engine oil filler neck to aid installation and help prevent O-ring damage.
4. Install the FLLCDUO oil filler cap onto the engine and verify the cap is fully seated and locked.
5. Apply high-quality thread sealant to the 1/8 NPT threads of the AN06-02MS90 fitting already installed on the completed return hose.
6. Install the AN06-02MS90 return-hose fitting into the installed FLLCDUO oil filler cap and tighten to 110 in-lbs.
7. Verify the return hose is routed without kinks, twists, excessive tension, or side load on the fitting.

AN06-02MS90 is a 1/8 NPT fitting and requires high-quality thread sealant. Tighten it to 110 in-lbs. Do not apply thread sealant to the ODU O-ring or its sealing surface.

12. Secure the Hoses

1. Secure the pressure and return hoses with zip ties, clamps, or appropriate existing mounting points.
2. Support the hoses at regular intervals to prevent movement, chafing, abrasion, or contact with surrounding components.
3. After securing the hoses, verify the routing has not created any kinks, twists, tight bends, or side loads on the fittings.
4. Confirm adequate clearance remains from exhaust components, steering and suspension components, driveline components, sharp edges, and excessive heat sources.

Keep Removed Factory Components in the Vehicle

Important: Place all factory components removed during installation and not reinstalled into a labeled bag and keep the bag in the vehicle. This includes factory plugs, fittings, sealing washers, O-rings, mounting hardware, and any other original components removed to install the bypass filtration system.

Final Inspection

• Correct mounting option installed
• Filter housing securely mounted
• Mounting bracket securely mounted
• Correct pressure-port option installed
• TM1275B installed to 60 in-lbs with D12 sealing washer and without NPT thread sealant where applicable
• AN06-02MP90 installed in the center branch of TM1275B with high-quality thread sealant and tightened to 110 in-lbs where applicable
• Factory oil pressure switch/sensor installed into TM1275B to 60 in-lbs without NPT thread sealant where applicable
• Factory oil temperature sensor reinstalled in the engine oil temperature port where applicable
• Electrical connectors reconnected to both the oil pressure switch/sensor and oil temperature sensor where applicable
• AN06-06FJ tightened to 60 in-lbs, loosened, then re-tightened to 110 in-lbs where applicable
• Oil filler cap return fitting installed with thread sealant and tightened to 110 in-lbs
• Pressure hose connected to filter housing IN
• Return hose connected to filter housing OUT
• Pressure hose secured
• Return hose secured
• No hose contact with sharp edges
• No hose contact with moving components
• No hose contact with excessive heat sources
• Oil level checked
• Add oil as necessary

Initial Startup

1. Add the appropriate type and quantity of engine oil to bring the engine oil level to the proper operating range before starting the engine.
2. Start the engine.
3. Verify oil pressure.
4. Inspect the entire bypass oil filtration system for leaks.
5. Verify adequate hose clearance with the engine running. Ensure the hoses are clear of moving components, sharp edges, and excessive heat sources.
6. Allow the engine to run for 10–15 minutes to purge air from the bypass oil filtration system and help ensure an accurate engine oil level reading.
7. Shut the engine off.
8. Check the engine oil level within a few minutes after shutdown.
9. Add engine oil as necessary to bring the oil level to the proper operating range.
10. Perform a final inspection of the entire installation. Verify all fittings are tight, all hoses are properly secured, the filter housing is securely mounted, and there are no leaks.

Oil level note: The oil level may show high if the vehicle sits for an extended period before checking.

Important: Failure to add engine oil before starting the engine may result in severe engine damage or engine failure. Damage caused by operating the engine with an insufficient oil level is not covered by Insane Diesel.

Maintenance

Bypass Filter Element Replacement

This kit uses an EXTREME1 bypass filter on a diesel engine. Replace the engine bypass filter element every 15,000 miles, 250 hours, or once per year, whichever comes first.

Inspect the hoses, fittings, filter housing, pressure connection, oil filler cap return, and mounting hardware during every engine oil change and during regular vehicle maintenance. Follow the vehicle manufacturer's recommended engine oil service interval and oil specification.

Extending Oil Change Intervals

For every 100,000 miles already on the engine, Insane Diesel recommends completing at least two regular scheduled engine oil, full-flow oil filter, and bypass filter changes before extending oil or filter service intervals through oil analysis.

No matter what anyone tells you, the only way to know when you can safely run longer on the same oil is through condition-based monitoring with oil analysis. Every engine will respond differently to bypass filtration, and oil analysis provides the information needed to understand the unique trends and condition of your engine and oil.

In order to extend your oil and filter change intervals, you have to get your oil clean first. Once the oil is clean, oil and filter change intervals may be extended based on oil-analysis results. No filter cleans better than Insane Diesel's EXTREME filter.