Installation Video / Reference Videos

Mercedes Sprinter OM642 Installation Video

Use the video references along with this written guide. If the written guide and video differ, verify the correct procedure before completing installation.

Installation Overview

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.
• Verify the supplied oil filter cap, oil filler cap, gasket, fittings, hose, filter housing, mounting bracket, and mounting hardware are correct for this kit.
• Verify the bypass filter housing contains the filter element, lid O-ring, lid bolt washer O-ring, and all required sealing components.
• Plan the mounting location and complete pressure and return hose routing before cutting the supplied hose.
• 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 EXTREME2 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 bypass filtration system performance.

For premium engine protection, Insane Diesel recommends Lorenzo's Oil™ high-performance engine oil. To further support fuel system cleanliness, injector performance, and overall engine efficiency, Insane Diesel also recommends Lorenzo's Oil™ Fuel Additive as part of your regular maintenance routine.

To learn more about Lorenzo's Oil™ and Lorenzo's Oil™ Fuel Additive, visit www.insanediesel.com.

Required Tools

• Basic mechanic tool set.
• Inch-pound torque wrench.
• Foot-pound torque wrench.
• Crow's foot wrenches.
• Hose cutting tool or equivalent.
• Oil filter cap removal tool, if applicable.
• Drill.
• Center punch.
• Small pilot drill bit.
• 13/32 in. drill bit for the supplied 3/8"-16 through-bolt mounting hardware used in Step 5.
• High-quality thread sealant for verified NPT/tapered pipe threads, including AN06-04MS90, AN06-02MS45, and AN06-02MS90.
• Blue medium-strength threadlocker, such as Loctite 242 or equivalent, for mounting hardware where applicable.
• Zip ties or clamps for hose routing and securing.

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 HX2SHBK housing is shown as the gallery reference. Blue and red housing color options and the OVW filler-cap gasket are intentionally not shown.

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, oil filter cap pressure location, and oil filler cap return location. Measure and build the hoses before final assembly. Install the ZBRCKX12 mounting bracket onto the vehicle first, then assemble the filter housing, install the housing fittings and hoses, mount the completed housing onto the already-installed bracket, route the hoses, and complete the engine-side pressure and return connections.

1. Find the Filter Housing Location

Before permanently mounting the bracket, identify a suitable mounting location and verify the supplied hose can be routed safely between the filter housing, oil filter cap pressure source, and oil filler cap return location.

Mounting Location Note: The filter housing may be installed in any suitable location that provides adequate clearance, safe hose routing, and access for future filter service. Depending on the mounting location selected, additional hose may be required beyond the hose supplied with the kit. Additional 3/8" braided nylon hose is available by the foot on our website: 3/8" Braided Nylon Hose (Sold by the Foot) – Insane Diesel.

Locate the preferred mounting location on the passenger side of the engine compartment along the inner fender, as shown in the reference photo. Before drilling, verify there is adequate clearance for the filter housing, hose routing, hood closure, and future filter servicing.

• Verify there is adequate structure for the mounting bracket and filter housing.
• Verify the supplied hose can reach the oil filter cap pressure source and oil filler cap return location.
• Verify adequate clearance for the filter housing, hoses, hood, wiring, suspension and steering components where applicable, driveline components, exhaust components, sharp edges, and excessive heat sources.
• Confirm the filter housing lid can be removed without interference for future filter service.
• Inspect both sides of the mounting surface before drilling.

2. Find the Oil Pressure Location

OM642 Oil Pressure Filter Cap Tips

• Remove your stock filter cap and remove the old stock filter.
• Use the O-rings that come with the new stock filter on the Insane Diesel filter cap.
• Carefully remove the center part of your stock filter cap and click it into the Insane Diesel filter cap.
• Insert the new stock filter in the Insane Diesel filter cap.
• For engines 2023 and older, a filter cap tool may help simplify removal.

The pressure source for this kit is the supplied PCVWS oil filter cap with the AN06-02MS45 pressure-port fitting. Verify the factory oil filter cap location, oil filter cap style, and pressure-hose routing before cutting the hose.

3. Find the Oil Return Location

Oil Return Filler Cap Tips

The supplied oil filler cap includes a high-quality gasket. Ensure the filler cap is securely installed at all times to prevent loosening due to vibration.

The return line connects to the supplied FLLCVWO2 oil filler cap using the OVW gasket and AN06-02MS90 return fitting. Verify the oil filler location and return-hose path before cutting the hose.

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.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

Hose Assembly Video

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 AN06-02MS45 fitting on the oil-filter-cap pressure end.
    AN06-04MS90 — Pressure Hose — AN06-02MS45
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 oil-filler-cap return end.
    AN06-04MS90 — Return Hose — AN06-02MS90
16. Before moving on, verify both completed hose assemblies are correctly identified: AN06-04MS90 — Pressure Hose — AN06-02MS45 and AN06-04MS90 — Return Hose — AN06-02MS90.
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. Install the Mounting Bracket on the Vehicle

1. Test fit the supplied mounting bracket ZBRCKX12 in the selected location.
2. Using the mounting bracket as a template, mark the mounting-hole locations.
3. Inspect both sides of the mounting surface to ensure no wiring, hoses, or other vehicle components will be damaged during drilling.
4. Use a center punch to mark the center of each mounting location.
5. Drill a small pilot hole at each marked location, then enlarge each hole using a 13/32 in. drill bit for the supplied 3/8"-16 bolts, flat washers, lock washers, and nuts.
6. Install the mounting bracket using the supplied 3/8"-16 bolts, flat washers, lock washers, and nuts. If preferred, compatible rivnuts/nutserts may be used instead, but rivnuts/nutserts and the required installation tool are not supplied with this kit.
7. Apply blue medium-strength threadlocker, such as Loctite 242 or equivalent, to the supplied 3/8"-16 mounting hardware and tighten the mounting fasteners to 35 ft-lbs.
8. Remove all metal shavings and drilling debris from the work area.
9. Verify the mounting bracket is securely fastened before installing the filter housing.

If using optional rivnuts/nutserts, follow the rivnut manufacturer's installation instructions and ensure the installed threads are suitable for the mounting hardware being used.

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, gaskets, sealing surfaces, 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

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.
4. Tighten the filter housing side mounting bolts to 35 ft-lbs.
5. Verify the filter housing is securely mounted, properly oriented for smooth hose routing, 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 Oil Filter Cap Pressure Fitting and Connect the Pressure Hose

1. Remove the stock oil filter cap and remove the old stock filter.
2. Use the O-rings that come with the new stock filter on the Insane Diesel filter cap.
3. Carefully remove the center part of the stock filter cap and click it into the Insane Diesel filter cap.
4. Insert the new stock filter in the Insane Diesel filter cap.
5. Inspect the supplied oil filter cap PCVWS and verify the O-ring is properly installed and fully seated in the O-ring groove.
6. Apply a thin coat of clean engine oil to the oil filter cap O-ring before installation. This will aid installation and help prevent O-ring damage.
7. Apply high-quality thread sealant to the NPT threads of the AN06-02MS45 fitting already installed on the completed pressure hose.
8. Install the AN06-02MS45 pressure-hose fitting into the PCVWS oil filter cap and tighten to 110 in-lbs.
9. Install the prepared oil filter cap assembly according to the vehicle manufacturer's service procedure and tighten the oil filter cap to the vehicle manufacturer's specified torque.
10. Verify the pressure hose is routed without kinks, twists, excessive tension, or side load on the fitting.

For engines 2023 and older, a filter cap tool may help simplify removal. AN06-02MS45 is an NPT fitting and requires high-quality thread sealant; tighten it to 110 in-lbs. Do not apply thread sealant to the oil filter cap O-ring or other non-NPT sealing surfaces.

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

1. Inspect the supplied oil filler cap FLLCVWO2 and verify the OVW gasket is properly installed and fully seated in the gasket groove.
2. Inspect the gasket for cuts, cracks, deformation, or other signs of damage. Replace the gasket if it is damaged or missing before proceeding.
3. Install the FLLCVWO2 oil filler cap onto the engine. Firmly press the cap downward until the gasket seats into the oil filler neck. The cap is fully seated when it can be rotated and locked into place.
4. Verify the oil filler cap is fully seated and locked before installing the return fitting.
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 FLLCVWO2 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.

The supplied oil filler cap gasket is designed to provide a snug seal. If the cap does not rotate into the locked position, apply additional downward pressure until the gasket seats properly. Ensure the filler cap is securely installed at all times to prevent loosening due to vibration. 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 filler-cap gasket or other non-NPT sealing surfaces.

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 original oil filter cap and its components, the original oil filler cap, factory plugs or fittings, sealing washers, O-rings, gaskets, hardware, and any other factory parts 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. If necessary, the original oil filter cap, oil filler cap, plugs, fittings, seals, and hardware can then be reinstalled in their original locations.

Final Inspection

• Filter housing securely mounted
• Mounting bracket securely mounted
• Vehicle-side through-bolt mounting hardware tightened to 35 ft-lbs
• Filter housing side mounting bolts tightened to 35 ft-lbs
• Oil filter cap pressure fitting installed with thread sealant and tightened to 110 in-lbs
• Oil filler cap return fitting installed with thread sealant and tightened to 110 in-lbs
• Oil filler cap securely seated and locked
• 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. Turn the engine off.
8. Check the engine oil level within a few minutes after shutdown to verify the correct oil level. The oil level may show high if the vehicle sits for an extended period before checking.
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.

Important: Failure to add engine oil before starting the engine will 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 the hoses, fittings, oil filter cap, oil filler cap, filter housing, 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.