Installation Video

Use the installation video along with this written guide. Verify the correct fitting configuration, mounting location, and hose routing before completing installation.

Installation and assembly should be performed by a qualified technician or certified mechanic familiar with engine oil system service, hose routing, and threaded fitting installation.

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. Quantities and descriptions are taken from the Kit Contents table. The black HX2SHBK housing is shown as the gallery reference. Other housing color options and the small included oil filler cap O-ring are intentionally not shown as separate gallery cards.

Torque Warning: 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. Install the ZBRCKX12 frame bracket onto the vehicle first, then assemble the filter housing, install the housing fittings and hoses, and mount the completed housing onto the already-installed bracket.

1. Find the Filter Housing Location

Multiple frame mounting locations are described in the installation video. Select the mounting location that provides the best combination of hose routing, filter housing clearance, and future filter service access for your application. If a different mounting location is selected instead of the recommended location, additional hose may be required. Additional 3/8 in. braided nylon hose can be ordered from Insane Diesel.

• 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.
• Verify there is adequate clearance for the filter housing, hose routing, suspension travel, brake lines, fuel lines, and other surrounding components.
• Confirm the filter housing can be serviced in the selected location without interference and that the housing lid can be removed for future filter service.

Under-the-Hood Mounting Option Note: If the EGR has been removed from the truck, the frame mount bracket may be installed under the hood on top of the EGR block-off plate using a longer M6 bolt in the center bolt location. This requires modifying the bracket by drilling a small hole in the center of the bracket.

2. Find the Oil Pressure Location

The pressure source uses the supplied TR2025 tee fitting system with AN06-06FJ, AN06-04MP, and AN06-04MP90.

Depending on the factory oil filter housing style, the oil pressure port may use either a front-facing or rear-facing oil pressure sensor. Verify the correct oil pressure sensor before removal by disconnecting the electrical connector and confirming it is a one-wire connector.

Rear-Facing Sensor Note: If the vehicle has the rear-facing oil pressure sensor, watch the installation video to identify and locate the correct factory oil pressure sensor before beginning pressure-port installation.

3. Find the Oil Return Location

The return line connects to the supplied FLLC67FO oil filler cap using the O67FO 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.

The kit includes 11 ft of LW06BK continuous hose. Verify the complete pressure and return routing before making either cut.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

Important: Recommended reference cut lengths are 7 ft and 4 ft. The supplied 11 ft LW06BK hose ships as one continuous uncut length to allow flexible mounting and routing.

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 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.
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.
16. Before moving on, verify both completed hose assemblies are correctly identified: AN06-04MS90 — Pressure Hose — AN06-06FJ 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 Frame Mount Bracket

1. Position the supplied ZBRCKX12 bracket at the recommended frame mounting location.
2. Inspect both sides of the frame before drilling to ensure no wiring, brake lines, fuel lines, coolant lines, hoses, or other components will be damaged.
3. Locate the existing frame mounting hole at the recommended mounting location and enlarge it to 21/64 in..
4. Position the ZBRCKX12 bracket using the enlarged mounting hole and use the bracket as a template to mark the location of the second mounting hole.
5. Center-punch the second mounting-hole location.
6. Drill a small pilot hole at the marked location, then enlarge the second hole to 21/64 in..
7. Remove all burrs, metal chips, 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 3/8 in. self-threading bolt threads.
9. Install the ZBRCKX12 bracket using the supplied 3/8 in. self-threading bolts.
10. Tighten both self-threading frame mounting bolts to 35 ft-lbs.
11. Verify the bracket is securely mounted and clear of surrounding components before installing the filter housing.

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 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 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, 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.

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 Tee Fitting and Connect the Pressure Hose

Pressure Port Components: Use the supplied TR2025 tee fitting with either the AN06-04MP or AN06-04MP90 pressure-port fitting. The completed pressure hose uses the AN06-06FJ hose-end fitting.

Front-Facing Sensor Note: Vehicles equipped with the front-facing oil pressure sensor require the AN06-04MP90 fitting. Install AN06-04MP90 into TR2025 before installing the tee into the engine. Some vehicles may also have a heat shield that interferes with installation. Carefully move the heat shield as needed, then return it to its original position after installation.

1. Locate the factory oil pressure sensor and disconnect its electrical connector.
2. Remove the factory oil pressure sensor.
3. Clean and inspect the factory oil pressure port. Make sure the threads are free of dirt, debris, old thread sealant, and damage.
4. For front-facing sensor applications only: Apply high-quality thread sealant to the NPT threads of AN06-04MP90, install it into TR2025, and tighten to 120 in-lbs.
5. Apply high-quality thread sealant to the NPT threads of TR2025. Install the tee into the factory oil pressure port and tighten to 120 in-lbs.
6. Apply high-quality thread sealant to the factory oil pressure sensor threads. Install the sensor into TR2025 and tighten to 120 in-lbs. On front-facing sensor applications, install the sensor into the center port of the tee.
7. If the pressure-port fitting was not installed in Step 4, apply high-quality thread sealant to the NPT threads of the selected AN06-04MP or AN06-04MP90 fitting. Hold TR2025 with a backup wrench and tighten the fitting into the tee to 120 in-lbs.
8. Connect the AN06-06FJ pressure-hose fitting to the installed pressure-port fitting. Hold the pressure-port fitting stationary with a backup wrench while tightening the hose fitting.
9. Tighten AN06-06FJ to 60 in-lbs, loosen it, then re-tighten to a final torque of 110 in-lbs.
10. Reconnect the factory oil pressure sensor electrical connector.
11. Verify the pressure hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

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

1. Inspect the supplied oil filler cap FLLC67FO and verify the O-ring O67FO is properly installed and fully seated in the O-ring groove.
2. Inspect the O-ring for cuts, cracks, deformation, or other signs of damage. Replace it if damaged or missing.
3. Apply a thin coat of clean engine oil to the new O-ring and to the inside of the engine oil filler neck to aid installation and help prevent O-ring damage.
4. Install the FLLC67FO oil filler cap onto the engine first. Firmly press the cap downward until the O-ring is fully seated in the oil filler neck.
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 FLLC67FO oil filler cap and tighten the 1/8 NPT connection to 110 in-lbs.
7. Verify the return hose is routed without kinks, twists, excessive tension, or contact with hot or moving components.

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 the filler-cap O-ring 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: Place all factory components removed during installation and not reinstalled into a labeled bag and keep the bag in the vehicle. This includes the original oil filler cap, sealing components, hardware, and any other original components removed to install the bypass filtration system.

The factory oil-pressure sensor installed into TR2025 remains in service and is not a loose retained component.

Final Inspection

• Filter housing securely mounted
• Frame mount bracket securely mounted
• TR2025 installed with thread sealant and torqued to 120 in-lbs
• Factory oil-pressure sensor installed into TR2025 with thread sealant and torqued to 120 in-lbs
• Selected pressure outlet fitting installed with thread sealant and torqued to 120 in-lbs
• AN06-06FJ tightened to 60 in-lbs, loosened, then re-tightened to 110 in-lbs
• Oil filler cap return installed and sealed
• AN06-02MS90 installed with thread sealant and torqued to 110 in-lbs
• 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 driveline 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.
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 connection, oil filler cap return, mounting hardware, bracket clearance, and hose routing 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.