Installation Videos

Installation Overview

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

Choose Your Installation Path

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 images below. Filter housing color options and bundled O-rings are intentionally not shown as separate gallery cards. The mounting-bracket cards are configuration-specific.

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-port style, and oil return location. Measure and build the hoses before final assembly. For the ZBRCKX12 Frame Mount, install the bracket onto the vehicle first, then mount the completed filter housing with its hoses installed onto the already-mounted bracket. For the SA_D66 Under-the-Hood configuration, assemble the filter housing and install the hoses first, attach SA_D66 to the assembled housing, then mount the completed housing/bracket assembly to the engine.

1. Find the Filter Housing Location and Confirm the Mounting Configuration

Frame Mount: Use ZBRCKX12. This is also the required mounting configuration for vehicles equipped with factory dual alternators.

Under-the-Hood: Use SA_D66. Do not use this configuration on vehicles equipped with the factory dual alternator option.

• For Frame Mount installations, select a suitable frame mounting location as close to the factory oil filter as practical.
• For Under-the-Hood installations, locate the factory dual alternator mounting location shown in the reference photos. These factory mounting bosses are used to secure SA_D66.
• Verify adequate structure for the filter housing and mounting bracket.
• Verify pressure- and return-hose reach before drilling or permanently mounting the bracket.
• Verify adequate filter-housing and lid clearance for future service.
• For Under-the-Hood installations, verify adequate hood clearance.
• Verify clearance from wiring, coolant lines, suspension and steering components where applicable, driveline components, exhaust components, sharp edges, and excessive heat sources.
• Inspect both sides of the selected mounting surface before drilling.

2. Find and Identify the Oil Pressure Location

Duramax engines may be equipped with either a straight-thread oil pressure port plug or an NPT oil pressure port plug. Remove or loosen the plug and use the descriptions below to identify which pressure port option is installed on your engine.

Straight Thread Plug: Has a flat shoulder or ledge that stops against the engine, may include a washer, crush washer, or O-ring, and requires the Straight Thread Oil Pressure Port option.

NPT Plug: Does not have a washer, crush washer, or O-ring and uses tapered pipe threads. This configuration requires the NPT Oil Pressure Port option.

Pressure Port Plug Removal Tip

Some customers find this plug easy to remove, while others find it difficult. Insane Diesel recommends removing the plug to verify the thread style before ordering a kit.

• Some customers suggest cutting an Allen wrench shorter to create additional room for a breaker bar or other leverage device.
• Some customers have applied penetrating oil to the plug, then used a brass hammer to lightly tap the fitting before attempting removal.
• Some customers have used a breaker bar to help remove the plug after applying penetrating oil and lightly tapping the fitting.
• Some customers have found that removing the rear two differential mounting bolts allows the differential to drop slightly, providing a few additional inches of clearance. This may allow enough room to use a standard Allen socket with a breaker bar to remove the oil port plug. Heat may also be necessary to assist with removing the oil port plug, especially if the plug is tight, corroded, or has thread sealant applied from the factory. Important: Support the differential properly before removing any mounting hardware. Do not allow the differential to hang by the axle shafts, driveshaft, wiring, hoses, or surrounding components. Use care when applying heat near oil, wiring, rubber components, seals, fuel lines, brake lines, and other heat-sensitive parts. Reinstall and tighten all differential mounting hardware according to the vehicle manufacturer’s service procedure before placing the vehicle back into service.

Use care when applying force to the plug or surrounding components. Do not use excessive force that could damage the plug, fitting, threads, or surrounding engine components.

3. Find the Oil Return Location

2001–2016 Return: Use the supplied FLLCDUO oil filler cap with ODU and AN06-02MS90.

2017–2019 Factory Oil-Pan Drain Return: Use the oil-pan drain location with MD175, O12, and AN06-02MS90.

2017–2019 Aftermarket Oil-Pan Return: If the vehicle has a compatible aftermarket oil pan with a 1/8 in. NPT return port, the supplied AN06-02MS90 may be installed directly into that return port using high-quality thread sealant.

2017–2019 VSE CCV Upgrade Return: If the vehicle is equipped with a compatible VSE CCV Upgrade, do not use MD175. The VSE oil filler cap must be drilled and tapped to 1/8 in. NPT so the supplied AN06-02MS90 return-hose fitting can be installed into the oil filler cap for the return connection.

Verify the correct return location and planned return-hose routing 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.

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 and the supplied AN06-06FJ fitting on the engine pressure-port 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 the supplied AN06-02MS90 fitting on the vehicle return end. This hose assembly is used for the 2001–2016 oil-filler-cap return, the 2017–2019 MD175 oil-pan drain return, a compatible 2017–2019 aftermarket oil-pan 1/8 in. NPT return, and the compatible 2017–2019 VSE CCV Upgrade return.
    AN06-04MS90 — Return Hose — AN06-02MS90
16. Before moving on, verify both completed hose assemblies are correctly identified.
17. Verify both completed hose assemblies are free from kinks and twists.

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. Install the Selected Mounting Bracket

5A. Frame Mount — ZBRCKX12

1. Select a suitable frame mounting location as close to the factory oil filter as practical. Before drilling or mounting the bracket, confirm there is adequate hose length to route between the filter housing, oil pressure source, and oil return location.
2. Position the supplied ZBRCKX12 frame mounting bracket against the frame rail and use the bracket as a template to mark the mounting holes.
3. Before drilling, inspect both sides of the frame to verify no vehicle components will be damaged.
4. Use a center punch to mark the center of each mounting location.
5. Drill a small pilot hole at each marked location.
6. Enlarge each hole using a 21/64 in. drill bit for the supplied 3/8 in. self-threading frame mounting bolts.
7. Remove all burrs, metal shavings, and drilling debris from the mounting holes and surrounding work area.
8. Apply blue medium-strength threadlocker, such as Loctite 242 or equivalent, to the supplied frame mounting bolt threads.
9. Install the ZBRCKX12 bracket using the supplied 3/8 in. self-threading frame mounting bolts.
10. Tighten the self-threading frame mounting bolts to 35 ft-lbs.
11. Verify the bracket is securely mounted before installing the filter housing.

5B. Under-the-Hood — SA_D66

1. Locate the factory dual alternator mounting location shown in the reference photo. These factory mounting bosses are used to secure the supplied Under-the-Hood mounting bracket SA_D66.
2. Verify the factory mounting bosses and surrounding area provide adequate clearance for the completed filter housing and bracket assembly.
3. Do not install SA_D66 onto the engine at this time. Assemble the filter housing and install the hoses first, then install SA_D66 onto the assembled filter housing in Step 8B before mounting the completed assembly to the engine.

Dual Alternator Restriction: Do not use this mounting configuration on vehicles equipped with the factory dual alternator option.

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 O-rings, sealing surfaces, straight-thread fittings, or AN flare connections.

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 onto the Installed Bracket

8A. Frame Mount — 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-mounted ZBRCKX12 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, then tighten the filter housing mounting bolts to 35 ft-lbs.
4. Verify the filter housing is securely mounted and the housing lid can be removed for future service.

8B. Under-the-Hood — SA_D66

1. With the pressure and return hoses already installed on the filter housing, position SA_D66 against the threaded mounting bosses on the bottom of the filter housing.
2. Apply blue medium-strength threadlocker to the filter housing mounting bolt threads.
3. Install the filter housing mounting bolts through SA_D66 into the bottom threaded mounting bosses and tighten to 18 ft-lbs.
4. Feed the pressure and return hoses toward their previously identified engine connection points.
5. Position the completed filter housing and SA_D66 bracket assembly at the factory mounting bosses.
6. Apply blue medium-strength threadlocker, such as Loctite 242 or equivalent, to the supplied SA_D66 engine-side mounting bolt threads.
7. Install the supplied mounting bolts and tighten them evenly until the bracket is fully seated against the mounting surface.
8. Torque the SA_D66 engine-side mounting bolts to 35 ft-lbs.
9. Verify the completed housing/bracket assembly is securely mounted and that the housing lid can be removed for future filter service without interference from surrounding engine components.

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 Correct Oil Pressure Port Fitting and Connect the Pressure Hose

10A. Straight Thread Oil Pressure Port

Straight Thread Components: Use 6MBPRR with O16, AN06-02MP90, and the AN06-06FJ already installed on the completed pressure hose.

1. Verify the supplied O16 O-ring is properly installed and fully seated on 6MBPRR.
2. Inspect the O-ring for cuts, cracks, deformation, or other signs of damage. Replace it if damaged or missing.
3. Install 6MBPRR into the factory oil pressure port and tighten to 60 in-lbs. Do not apply thread sealant to the O-ring-sealed straight-thread fitting.
4. Apply high-quality thread sealant to the NPT threads of AN06-02MP90.
5. Install AN06-02MP90 into 6MBPRR and tighten to 110 in-lbs. Hold 6MBPRR with a backup wrench while tightening AN06-02MP90 so the 60 in-lb straight-thread adapter does not rotate or become over-tightened.
6. 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.
7. Tighten AN06-06FJ to 60 in-lbs, loosen the fitting, then re-tighten to a final torque of 110 in-lbs.
8. Verify the pressure hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

Do not apply thread sealant to the O-ring-sealed 6MBPRR. AN06-02MP90 is an NPT fitting and requires high-quality thread sealant; tighten it to 110 in-lbs. Do not apply thread sealant to the AN06-06FJ AN flare connection.

10B. NPT Oil Pressure Port

NPT Components: Use 6MBPTRR, AN06-02MP90, and the AN06-06FJ already installed on the completed pressure hose.

1. Inspect the factory oil pressure port threads and ensure they are clean and free of dirt, oil, old thread sealant, or debris before installation.
2. Apply high-quality thread sealant to the NPT threads of 6MBPTRR.
3. Install 6MBPTRR into the factory oil pressure port and tighten to 130 in-lbs.
4. Apply high-quality thread sealant to the NPT threads of AN06-02MP90.
5. Install AN06-02MP90 into 6MBPTRR and tighten to 110 in-lbs. Hold 6MBPTRR with a backup wrench while tightening AN06-02MP90 so the adapter does not rotate.
6. 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.
7. Tighten AN06-06FJ to 60 in-lbs, loosen the fitting, then re-tighten to a final torque of 110 in-lbs.
8. Verify the pressure hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

6MBPTRR and AN06-02MP90 are NPT fittings. Apply high-quality thread sealant to both fittings. Tighten 6MBPTRR to 130 in-lbs and AN06-02MP90 to 110 in-lbs. Do not apply thread sealant to the AN06-06FJ AN flare connection.

11. Install the Correct Oil Return and Connect the Return Hose

11A. 2001–2016 Oil Filler Cap Return

1. Complete this procedure for 2001–2016 vehicles using the oil filler cap return.
2. Inspect the supplied FLLCDUO oil filler cap and verify the ODU O-ring is properly installed and fully seated in the O-ring groove.
3. Inspect the O-ring for cuts, cracks, deformation, or other signs of damage. Replace it if damaged or missing before proceeding.
4. Install the FLLCDUO oil filler cap onto the engine and verify the cap is fully seated.
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 to 110 in-lbs. Do not apply thread sealant to the ODU O-ring or other non-NPT sealing surfaces.

11B. 2017–2019 Factory Oil-Pan Drain Return — MD175

Use this procedure when returning through the factory oil-pan drain location with MD175.

1. Place a suitable drain pan beneath the oil pan and remove the factory drain plug.
2. Allow the engine oil to drain completely.
3. Verify the O12 O-ring is installed on the MD175 fitting and is clean, undamaged, and properly positioned.
4. The AN06-02MS90 is already installed on the completed return hose from Step 4. Apply high-quality thread sealant to the 1/8 NPT threads of AN06-02MS90.
5. Install MD175 onto AN06-02MS90 and tighten the AN06-02MS90 connection to 110 in-lbs.
6. Install the assembled MD175 and AN06-02MS90 fitting into the oil-pan drain opening.
7. Tighten MD175 to a maximum of 60 in-lbs.
8. Verify the O12 O-ring is properly seated and is not being squeezed out from between the MD175 fitting and the oil pan.
9. Verify the return hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.
10. Refill the engine after installation is complete.

11C. 2017–2019 Aftermarket Oil-Pan Return

1. Complete this procedure only when the vehicle is equipped with a compatible aftermarket oil pan that provides a 1/8 in. NPT return port.
2. Verify the aftermarket oil-pan return port is clean and free from debris.
3. The AN06-02MS90 is already installed on the completed return hose from Step 4.
4. Apply high-quality thread sealant to the 1/8 NPT threads of AN06-02MS90.
5. Install AN06-02MS90 directly into the compatible aftermarket oil-pan return port and tighten to 110 in-lbs.
6. Verify the return hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

11D. 2017–2019 VSE CCV Upgrade Return

1. Complete this procedure only if the 2017–2019 vehicle is equipped with a compatible VSE CCV Upgrade.
2. Do not install MD175 when the compatible VSE CCV Upgrade return is used.
3. Drill and tap the VSE oil filler cap to 1/8 in. NPT for the supplied AN06-02MS90 return-hose fitting.
4. Verify the drilled and tapped return port in the VSE oil filler cap is clean and free from debris before installing the return fitting.
5. The AN06-02MS90 is already installed on the completed return hose from Step 4.
6. Apply high-quality thread sealant to the 1/8 NPT threads of AN06-02MS90.
7. Install AN06-02MS90 into the drilled and tapped 1/8 in. NPT return port in the VSE oil filler cap and tighten to 110 in-lbs.
8. Verify the return hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

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 the factory oil pressure-port plug, oil filler cap, factory oil drain plug when removed for the 2017–2019 MD175 return, sealing washers, O-rings, differential mounting hardware if removed during pressure-port access, and any other original components removed to install the bypass filtration system.

Final Inspection

• Correct mounting configuration installed
• Filter housing securely mounted
• Mounting bracket securely mounted
• Correct pressure port option installed
• Straight-thread pressure adapter installed without NPT sealant where applicable
• NPT pressure fittings installed with high-quality thread sealant where applicable
• AN06-06FJ tightened to 60 in-lbs, loosened, then re-tightened to 110 in-lbs
• Correct oil return installed for the vehicle year and configuration
• 2001–2016 oil filler cap return AN06-02MS90 installed with thread sealant and tightened to 110 in-lbs where applicable
• 2017–2019 MD175 return installed with O12, MD175 at 60 in-lbs maximum, and AN06-02MS90 at 110 in-lbs where applicable
• 2017–2019 aftermarket oil-pan return AN06-02MS90 installed into a compatible 1/8 in. NPT return port with thread sealant and tightened to 110 in-lbs where applicable
• Compatible 2017–2019 VSE CCV return installed without MD175; VSE oil filler cap drilled and tapped to 1/8 in. NPT; AN06-02MS90 installed with thread sealant and tightened to 110 in-lbs where applicable
• 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. Follow the procedure in the vehicle owner's manual for checking the engine oil level for the specific model year and application. Oil-level checking procedures may differ across the 2001–2019 model-year range.
9. Check the engine oil level according to the procedure specified in the vehicle owner's manual.
10. Add engine oil as necessary to bring the oil level to the proper operating range.
11. 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: Always follow the vehicle owner's manual for the correct engine oil-level checking procedure for the specific model year and application. Procedures may differ across the 2001–2019 model-year range.

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 EXTREME2 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 hoses, fittings, filter housing, pressure connection, oil filler cap return, and mounting hardware during engine oil changes and scheduled service intervals.

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.