Installation Video

Installation Video Notice

The installation video demonstrates the Under-the-Hood Mount configuration. While mounting locations differ, hose assembly, fitting installation, filter housing setup, and overall oil system installation procedures are substantially the same for both Under-the-Hood and Frame Mount kits.

Installation Overview

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

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. Other housing color options and small included O-rings are intentionally not shown as separate gallery cards.

Mounting Kit Note

The mounting bracket, mounting hardware, and hose length included with your kit are determined by the mounting option ordered.

• Under-the-Hood kits include the IM_ELB bracket, mounting hardware, and 7 ft hose.
• Frame Mount kits include the ZBRCKX12 bracket, supplied 3/8 in. self-threading frame mounting bolts, and 12 ft 5 in hose.

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 pressure location, oil return location, and mounting 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 IM_ELB Under-the-Hood Mount follows the same basic sequence: install the bracket onto the intake manifold first, then mount the completed filter housing with its hoses installed onto the already-mounted bracket.

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

• Under-the-Hood Mount: Use the IM_ELB bracket, supplied mounting hardware, and 7 ft hose. This option is not compatible with dual alternator equipped vehicles.
• Frame Mount: Use the ZBRCKX12 bracket assembly, supplied 3/8 in. self-threading frame mounting bolts, and 12 ft 5 in hose. Use this version if the truck is equipped with dual alternators.
• 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, verify adequate hood clearance and confirm the housing lid can be removed for future filter service.
• Before drilling or installing mounting hardware, inspect both sides of the mounting surface to verify no vehicle components will be damaged.

2. Find the Oil Pressure Location

1. Locate the factory oil pressure port plug on top of the oil filter cap, as shown in the reference photo or installation video.
2. Verify access to the pressure port and the planned hose-routing path before removing the factory plug.
3. The pressure-port assembly uses the supplied O10 O-ring, TM181215 straight-thread pressure-port fitting, and AN06-02MS90 NPT pressure-port adapter.

3. Find the Oil Return Location

1. Locate the oil filler cap return location shown in the reference photo or installation video.
2. Verify the supplied FLLCCO oil filler cap assembly, OCC fill-cap O-ring, and AN06-02MS90 fill-cap adapter are correct for the kit.
3. Verify the planned return-hose path from the filter housing OUT port to the oil filler cap return fitting 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.

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

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

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 the hose is not pushed out of the socket while threading the barb into 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 one AN06-02MS90 fitting on the engine-side pressure end.
15. Return Hose Assembly: Install the remaining AN06-04MS90 fitting on the filter-housing end of the return hose and the remaining AN06-02MS90 fitting on the oil-filler-cap return end.
16. Before moving on, verify both completed hose assemblies are correctly identified: AN06-04MS90 — Pressure Hose — AN06-02MS90 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. Under-the-Hood Bracket Installation

1. Locate the under-the-hood mounting location shown in the reference photo or installation video. Verify there is adequate clearance for the filter housing, hose routing, hood closure, and future filter servicing.
2. Position the supplied IM_ELB Under-the-Hood Bracket at the recommended mounting location on the intake manifold. Verify the bracket sits flat and can be installed without interfering with surrounding vehicle components.
3. Before installing the bracket, inspect the mounting area to ensure no wiring, hoses, or other vehicle components will be damaged during installation.
4. Apply blue medium-strength threadlocker, such as Loctite® 242 or equivalent, to the supplied IM_ELB bracket mounting bolt threads.
5. Install the IM_ELB Under-the-Hood Bracket onto the intake manifold using the supplied mounting hardware.
6. Tighten the bracket mounting hardware to 35 ft-lbs.
7. Verify the bracket is securely mounted, properly positioned, and maintains adequate clearance for the filter housing, hose routing, hood closure, and future filter servicing.

5B. Frame Mount Bracket Installation

1. Position the supplied ZBRCKX12 Frame Mount Bracket 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.

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. Under-the-Hood Mount

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 completed filter housing onto the already-mounted IM_ELB Under-the-Hood Bracket using the bottom threaded bosses on the filter housing.
3. Apply blue medium-strength threadlocker, such as Loctite® 242 or equivalent, to the supplied filter housing mounting bolt threads.
4. Install the supplied filter housing mounting bolts and tighten them to 18 ft-lbs.
5. Verify the filter housing is securely mounted, the pressure and return hoses have smooth routing paths without twists or excessive tension, and the housing lid can be removed for future filter servicing.
6. Verify adequate clearance from the hood, wiring, hoses, and surrounding engine components.

Important: The 18 ft-lb filter housing mounting torque applies to brackets using the bottom threaded bosses of the filter housing.

8B. Frame Mount

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 completed filter housing onto the already-mounted ZBRCKX12 Frame Mount 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, properly oriented for 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 Pressure Port Fitting and Connect the Pressure Hose

1. Clean the area around the factory oil pressure port plug before removing it.
2. Remove the factory oil pressure port plug from the top of the oil filter cap.
3. Install the supplied O10 O-ring onto the TM181215 pressure-port fitting. Do not apply thread sealant to the O10 O-ring.
4. Install the TM181215 straight-thread pressure-port fitting into the oil filter cap pressure port and tighten to 60 in-lbs. Do not apply NPT thread sealant to the TM181215 connection.
5. Apply high-quality thread sealant to the 1/8 NPT threads of the AN06-02MS90 fitting already installed on the engine-side end of the completed pressure hose.
6. Install the AN06-02MS90 pressure-port adapter into the TM181215 pressure-port fitting and tighten to 110 in-lbs. Hold TM181215 itself with a backup wrench while tightening the higher-torque adapter so the 60 in-lb pressure-port fitting does not rotate or become over-tightened.
7. Verify the completed pressure hose is fully connected to the installed pressure-port adapter.
8. Verify the completed pressure-port fitting assembly has adequate clearance from surrounding engine components, moving components, sharp edges, exhaust components, and excessive heat sources.

Important: TM181215 is a straight-thread, O-ring-sealed fitting tightened to 60 in-lbs; do not apply NPT thread sealant to that connection. AN06-02MS90 is a 1/8 NPT fitting installed on the engine-side end of the completed pressure hose and requires high-quality thread sealant; tighten it to 110 in-lbs.

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.

Important: 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 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 the factory pressure-port plug or fitting, oil filler cap, sealing washers, O-rings, mounting hardware, and any other original 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 pressure-port plug or fitting, oil filler cap, seals, hardware, and other factory 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
• TM181215 installed with O10, no NPT sealant, and tightened to 60 in-lbs
• Pressure-port AN06-02MS90 on the engine-side end of the completed pressure hose installed with thread sealant and tightened to 110 in-lbs
• Oil filler cap return AN06-02MS90 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 complete 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 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.