Installation Videos

Frame Mount Installation Video

Under-the-Hood Installation Video

Use the video that matches your mounting configuration together with this written guide.

Installation Overview

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

Choose Your Installation Path

Frame Mount — ZBRCKX12

Use the Frame Mount installation section when the kit includes the ZBRCKX12 bracket or when the vehicle has factory dual alternators.

Under-the-Hood — SA_D66

Use the Under-the-Hood installation section when the kit includes the SA_D66 bracket and the vehicle does not have the factory dual alternator option.

Oil Return Options

Standard Oil Drain Plug / Pan Return: Uses MD175, O12, and AN06-02MS90.

Aftermarket Oil Pan Return: For applicable aftermarket oil pans equipped with a return port, do not install MD175. The kit already includes the AN06-02MS90 required for the aftermarket oil pan return port.

VSE CCV Upgrade Return: Optional return for compatible 2017-Present L5P engines equipped with the VSE CCV upgrade kit. Verify compatibility before installation. The AN06-02MS90 return-hose fitting installs directly into the compatible 1/8 NPT VSE return location.

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. Mounting-bracket cards are configuration-specific. Small bundled O-rings are intentionally not shown as separate gallery cards.

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.

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.

Installation Procedure

Follow the steps below in this order. First identify the filter housing location, pressure location, return location, mounting configuration, and oil-return option. 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. The SA_D66 Under-the-Hood configuration uses its kit-specific mounting procedure.

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 the factory dual alternator option.

Under-the-Hood: Use SA_D66. This configuration is not compatible with vehicles equipped with the factory dual alternator option due to limited mounting space.

• Verify clearances for the filter housing, hoses, and future filter servicing from moving components, steering and suspension components, brake lines, fuel lines, coolant lines, wiring harnesses, exhaust components, and other excessive heat sources.
• For Under-the-Hood installations, also verify adequate hood clearance.
• Confirm the filter housing can be serviced without interference and the housing lid can be removed for future service.
• Confirm there is adequate hose length for the selected combination of mounting configuration and return option.
• Before drilling or installing mounting hardware, inspect both sides of the selected mounting surface to verify no vehicle components will be damaged.

2. Find the Oil Pressure Location

1. Locate the factory oil pressure port.
2. Verify access for a 10 mm Allen socket or Allen wrench and verify the planned hose-routing path before removing the factory plug.
3. The pressure-port assembly uses AN06-20MMx1.5 with the O20 O-ring and the AN06-06FJ90 swivel fitting.

3. Find the Oil Return Location and Confirm the Return Option

Standard Oil Drain Plug / Pan Return: Uses the supplied MD175, O12, and AN06-02MS90.

Aftermarket Oil Pan Return: For applicable aftermarket oil pans equipped with a return port, the supplied MD175 drain-plug fitting is not used. The supplied AN06-02MS90 on the completed return hose connects directly to the aftermarket oil pan return port.

VSE CCV Upgrade Return: Optional return for compatible 2017-Present L5P engines equipped with the VSE CCV upgrade kit. Verify compatibility before installation.

4. Measure and Build the Hoses

Before proceeding with Step 4, watch the Hose Assembly Video below so you are familiar with the correct reusable hose fitting assembly procedure.

The required pressure-hose and return-hose lengths depend on both the mounting configuration and the selected return option. Use the hose-length table immediately after the Hose Assembly Video before measuring or cutting the supplied hose.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

Hose Assembly Video

Hose Length by Configuration

Important: Hose requirements change depending on both the filter-housing mounting location and selected oil-return configuration. Use the correct row below before measuring or cutting hose.

Aftermarket Oil Pan Note: When the vehicle uses an applicable aftermarket oil pan with a return port, use the standard-pan mounting/routing path for the applicable vehicle configuration unless the actual installation requires additional routing clearance. The MD175 drain-plug fitting is not used. The supplied AN06-02MS90 connects the return hose to the aftermarket oil pan return port.

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: Assemble the pressure hose by installing one AN06-04MS90 fitting on the filter-housing end of the pressure hose and the supplied AN06-06FJ90 fitting on the engine pressure-port end of the pressure hose.
    AN06-04MS90 — Pressure Hose — AN06-06FJ90
15. Standard Pan Return Hose Assembly: Assemble the return hose by installing the remaining AN06-04MS90 fitting on the filter-housing end of the return hose and the supplied AN06-02MS90 fitting on the engine-side return end.
    AN06-04MS90 — Return Hose — AN06-02MS90
16. Aftermarket Oil Pan Return Hose Assembly: Assemble the return hose by installing the remaining AN06-04MS90 fitting on the filter-housing end of the return hose and the supplied AN06-02MS90 fitting on the aftermarket oil pan return end. The AN06-02MS90 connects directly to the aftermarket oil pan return port. Do not use MD175 with this configuration.
    AN06-04MS90 — Return Hose — AN06-02MS90
17. VSE CCV Upgrade Return Hose Assembly: Assemble the return hose by installing the remaining AN06-04MS90 fitting on the filter-housing end of the return hose and the supplied AN06-02MS90 fitting on the VSE return end.
    AN06-04MS90 — Return Hose — AN06-02MS90
18. Before moving on, verify the completed hose assemblies match the selected return option and are correctly identified.
19. 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. 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.
2. Position the supplied ZBRCKX12 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 and maintains adequate clearance from surrounding vehicle components.

5B. Prepare the Under-the-Hood Mounting Location — SA_D66

1. Locate the two factory threaded mounting bosses used for the factory dual alternator bracket.
2. Position the SA_D66 bracket against the mounting bosses only as needed to verify fitment, orientation, bolt access, hood clearance, wiring clearance, and future filter service access.
3. If needed, carefully unclip and reposition the adjacent wiring harness.
4. Do not permanently install the SA_D66 bracket onto the engine at this stage.
5. Set the bracket aside and continue with filter housing assembly and hose installation.

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 supplied AN06-04MS90 fittings.
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, or gasketed 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 onto the Installed Bracket

8A. Frame Mount — ZBRCKX12

1. With both hoses already installed on the filter housing, feed the pressure and return hoses toward their previously identified engine connection points.
2. Position the assembled filter housing onto the already-mounted ZBRCKX12 frame bracket.
3. Install the housing using the side mounting bosses and tighten the filter housing mounting bolts to 35 ft-lbs.
4. Verify the housing is securely mounted, properly oriented for hose routing, and the lid remains accessible for future service.

8B. Under-the-Hood — SA_D66

1. With the pressure and return hoses already installed on the filter housing, position the SA_D66 bracket onto 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 the SA_D66 bracket into the bottom threaded mounting bosses and tighten to 18 ft-lbs.
4. Move the complete filter-housing-and-bracket assembly into the previously verified Under-the-Hood mounting location.
5. If needed, carefully unclip and reposition the adjacent wiring harness for clearance.
6. Apply blue medium-strength threadlocker to the supplied SA_D66 bracket mounting bolts.
7. Install the complete assembly onto the two factory threaded mounting bosses and torque the bracket mounting bolts to 35 ft-lbs.
8. Verify the filter housing is firmly mounted, the hoses have smooth routing paths without kinks or excessive tension, and the housing lid can be removed for future service.
9. Verify adequate clearance from the hood, wiring, and 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 Oil Pressure Port Fitting and Connect the Pressure Hose

1. Remove the factory pressure-port plug using a 10 mm Allen wrench or socket.
2. Inspect the factory pressure-port threads after removing the stock pressure plug. Insane Diesel has found that some factory pressure-port threads may be slightly galled or rough after the factory plug is removed.
3. Verify the factory pressure-port threads are clear of debris. Inspect the supplied AN06-20MMx1.5 fitting and ensure the supplied O20 O-ring is present and seated against the fitting shoulder.
4. Thread AN06-20MMx1.5 into the factory oil pressure port until the O20 O-ring contacts both the fitting shoulder and the housing shoulder.
5. Once the O20 O-ring is touching both shoulders, tighten AN06-20MMx1.5 to 60 in-lbs while compressing the O-ring.
6. The AN06-06FJ90 is already installed on the completed pressure hose from Step 4. Connect AN06-06FJ90 to AN06-20MMx1.5.
7. While tightening AN06-06FJ90, hold AN06-20MMx1.5 with a backup wrench so the 60 in-lb adapter does not rotate or become over-tightened.
8. Tighten AN06-06FJ90 to 60 in-lbs, loosen the fitting, then re-tighten to a final torque of 110 in-lbs.
9. Verify the pressure hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

Important: AN06-20MMx1.5 is an O-ring-sealed aluminum straight-thread fitting. Verify the O20 O-ring is positioned between the fitting shoulder and the housing shoulder. Once the O-ring contacts both shoulders, tighten the fitting to 60 in-lbs while compressing the O-ring.

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

11A. Standard Oil Drain Plug / Pan Return

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.
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 AN06-02MS90 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 seated correctly and is not squeezed out of the sealing area.
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.

11B. Aftermarket Oil Pan Return

Aftermarket Oil Pan Compatibility Note: The bypass filtration kit works with applicable aftermarket oil pans equipped with a return port. The supplied MD175 drain-plug fitting is not needed when the aftermarket oil pan return port is used. The kit already includes the AN06-02MS90 required for this connection.

1. Drain the engine oil before removing the fitting from the aftermarket oil pan return port.
2. Locate the return port on the installed aftermarket oil pan and verify the port is clean and ready for the return connection.
3. Do not install the supplied MD175 drain-plug fitting for this configuration.
4. The AN06-02MS90 is already installed on the completed return hose from Step 4.
5. Apply high-quality thread sealant to the 1/8 NPT threads of AN06-02MS90.
6. Install the AN06-02MS90 return-hose fitting into the aftermarket oil pan return port and tighten to 110 in-lbs.
7. Verify the return hose follows a smooth routing path without kinks, twists, excessive tension, or contact with hot or moving components.

11C. VSE CCV Upgrade Return

1. Complete this procedure only if the vehicle is equipped with a compatible VSE CCV Upgrade Kit.
2. Verify the VSE oil filler cap has been drilled and tapped for a 1/8 in. NPT fitting and is free of machining 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 the AN06-02MS90 return-hose fitting directly into the compatible 1/8 NPT VSE return location and tighten to 110 in-lbs.
6. Orient the hose for a smooth routing path without placing excessive tension or side load on the fitting.
7. 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: After installation is complete, place all factory components removed during the installation into a labeled bag and keep the bag in the vehicle. This includes the factory pressure-port plug, factory oil drain plug if removed, sealing washers, O-rings, mounting hardware, and any other original components removed to install the bypass filtration system.

Keeping these original components with the vehicle allows the factory oil-system connections to be restored if an emergency or service situation requires the bypass system to be temporarily removed or bypassed.

Final Inspection

• Correct mounting configuration installed
• Correct return option installed
• Correct hose lengths used for the selected mounting and return configuration
• MD175 omitted when using aftermarket oil pan return
• Filter housing securely mounted
• 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
• AN06-20MMx1.5 installed with O20, no thread sealant, and tightened to 60 in-lbs
• AN06-06FJ90 tightened to 60 in-lbs, loosened, then re-tightened to 110 in-lbs
• Selected return fitting system installed and tightened
• Pressure hose connected to filter housing IN
• Return hose connected to filter housing OUT
• Engine oil refilled if drained during installation
• 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.
9. Check the engine oil level according to the vehicle owner's manual procedure before adding oil as necessary.
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: Engine-oil-level checking procedures and wait times may differ across the 2001–2026 model-year range. Always follow the vehicle owner's manual for the correct engine-oil-level checking procedure and wait time for the specific model year and application. 

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, return connection, 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.