Installation Video

Use this shared installation video together with the written section that matches your mounting configuration.

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. Mounting-bracket cards are configuration-specific.

Important Torque Note: Follow the verified torque specification and sealing method for each fitting. Do not apply thread sealant to AN flare connections, O-rings, sealing washers, gaskets, or other non-tapered sealing surfaces. 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 pressure location, 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. The SA_LB Under-the-Hood configuration follows a kit-specific sequence: prepare the mounting location first, assemble the filter housing, connect the housing fittings and hoses, mount the housing onto the SA_LB bracket using the bottom threaded bosses, and only then install the complete bracket-and-housing assembly onto the vehicle.

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

Frame Mount: Use ZBRCKX12. Use this configuration when the vehicle has dual alternators or a “Y” shaped radiator hose.

Under-the-Hood: Use SA_LB only when the vehicle does not have dual alternators or a “Y” shaped radiator hose.

• For Frame Mount installations, select a suitable frame mounting location as close to the factory oil filter as practical.
• Before drilling or installing mounting hardware, inspect both sides of the mounting surface to verify no vehicle components will be damaged.
• For Under-the-Hood installations, locate the under-the-hood mounting area shown in the reference photos.
• Verify clearances for the filter housing, the hoses, and for future filter servicing from moving components, steering and suspension components, brake lines, fuel lines, coolant lines, wiring harnesses, exhaust components or other excessive heat sources.
• For Under-the-Hood installations, also verify adequate hood clearance and radiator-hose clearance.
• Confirm the filter housing lid can be removed for future service.

2. Find the Oil Pressure Location

Oil Pressure Port Reference Video

The pressure source uses the supplied AN06-02MS45 fitting. The factory oil pressure port is located on the top of the factory oil filter housing. Locate the port shown in the reference photos and verify the planned hose-routing path before removing the factory plug or fitting.

3. Find the Oil Return Location

The return line connects to the supplied FLLCCO oil filler cap using the OCC 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.

Frame Mount: The kit includes 12 ft 5 in of LW06BK continuous hose. Under-the-Hood: The kit includes 7 ft 2 in of LW06BK continuous hose. Verify the complete pressure and return routing before making either cut.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

Important: The Frame Mount kit includes 12 ft 5 in of continuous LW06BK hose with recommended reference cut lengths of approximately 7 ft and 5 ft 5 in. The Under-the-Hood kit includes 7 ft 2 in of continuous LW06BK hose with recommended reference cut lengths of approximately 2 ft 7 in and 4 ft 6 in. Verify the actual pressure and return routing before making either cut.

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 engine pressure-port end of the pressure hose.
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 of the return hose.
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. 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. Position the supplied ZBRCKX12 at the selected frame mounting location and use the bracket as a template to mark the mounting-hole locations.
2. Before drilling, inspect both sides of the frame to verify no vehicle components will be damaged.
3. Use a center punch to mark the center of each mounting location.
4. Drill a small pilot hole at each marked location.
5. Enlarge each mounting hole using a 21/64 in. drill bit for the supplied 3/8 in. self-threading frame mounting bolts.
6. Remove all burrs, metal shavings, and drilling debris from the mounting holes and surrounding work area.
7. Apply blue medium-strength threadlocker, such as Loctite 242 or equivalent, to the supplied frame mounting bolt threads.
8. Install the ZBRCKX12 bracket using the supplied 3/8 in. self-threading frame mounting bolts.
9. Tighten the self-threading frame mounting bolts to 35 ft-lbs.
10. Verify the bracket is securely mounted and maintains adequate clearance from surrounding vehicle components.

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

1. Locate the Under-the-Hood mounting area and verify clearance for the complete SA_LB bracket and filter housing assembly.
2. Plan the pressure and return hose routing before assembling or installing the bracket and housing.
3. Test-fit the SA_LB bracket at the mounting location only as needed to confirm orientation, bolt access, hood clearance, radiator-hose clearance, wiring clearance, and future filter service access.
4. Do not permanently install the SA_LB bracket onto the vehicle at this stage.
5. Set the bracket aside and continue with filter housing assembly and hose installation.

Fitment Restriction: Do not install this configuration on vehicles with a “Y” shaped radiator hose or dual alternators.

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

Use high-quality thread sealant only on verified NPT/tapered pipe threads. Do not apply thread sealant to AN flare connections, O-rings, straight-thread fittings, sealing washers, gaskets, 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. 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 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. Mount the Housing to the SA_LB Bracket, Then Install the Complete Assembly

1. With both hoses already connected to the filter housing, position the SA_LB bracket onto the bottom threaded bosses of the EXTREME2 filter housing.
2. Apply blue medium-strength threadlocker to the filter housing mounting bolts.
3. Install the housing mounting bolts and torque them to 18 ft-lbs.
4. Orient the bracket and filter housing so the pressure and return hoses have smooth, large-radius bends and the housing lid remains accessible for service.
5. Move the complete SA_LB bracket, filter housing, and attached hose assembly into the previously verified Under-the-Hood mounting location.
6. Apply blue medium-strength threadlocker to the bracket mounting bolts where applicable.
7. Install the complete bracket-and-housing assembly onto the vehicle and torque the bracket mounting hardware to 35 ft-lbs.
8. Verify clearance from wiring, radiator hoses, hood, and surrounding engine components.
9. Confirm the filter housing is secure, the hoses are not twisted or under tension, and the housing lid remains accessible 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 Pressure Port Fitting and Connect the Pressure Hose

Installation Note: Before installing the oil pressure fitting, watch the installation video and follow the tips shown for installing the pressure fitting. If you would like to purchase the optional E452MF fitting to help make installation easier, it is available from Insane Diesel here: Fittings - E452MF.

1. Locate the factory oil pressure port on the top of the factory oil filter housing, as shown in the reference photos.
2. Remove the factory plug as required.
3. Inspect the AN06-02MS45 fitting installed on the completed pressure hose in Step 4 and verify the threads and sealing surfaces are clean and undamaged.
4. Apply high-quality thread sealant to the NPT threads of the AN06-02MS45 fitting installed on the pressure-hose end in Step 4.
5. Install AN06-02MS45 into the factory oil pressure port and tighten to 110 in-lbs.
6. Verify the pressure hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

AN06-02MS45 is an NPT fitting and requires high-quality thread sealant. Tighten it to 110 in-lbs. Do not apply thread sealant to AN flare connections or other non-NPT sealing surfaces.

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

1. Inspect the supplied FLLCCO oil filler cap and verify the OCC O-ring is properly installed and fully seated.
2. Inspect the OCC O-ring for cuts, cracks, deformation, or damage. Replace it if damaged or missing.
3. Install the FLLCCO oil filler cap onto the engine and verify the cap is fully seated.
4. Apply high-quality thread sealant to the 1/8 NPT threads of the AN06-02MS90 fitting already installed on the completed return hose.
5. Install the AN06-02MS90 return-hose fitting into the installed FLLCCO oil filler cap and tighten the 1/8 NPT connection to 110 in-lbs.
6. 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 the connection to 110 in-lbs. Do not apply thread sealant to AN flare connections, O-rings, 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 any factory pressure-port plug or fitting, oil filler cap, sealing washers, O-rings, mounting 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 factory pressure-port plug or fitting, oil filler cap, seals, hardware, and other original components can then be reinstalled in their original locations.

Final Inspection

• Correct mounting configuration installed
• 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 driveline components
• No hose contact with excessive heat sources
• Oil 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
• Pressure hose connected to filter housing IN
• Return hose connected to filter housing OUT
• 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.

The oil level may read high after the vehicle has been sitting for an extended period.

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 the hoses, fittings, filter housing, pressure-port connection, oil filler-cap return assembly, 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.