Installation Video

This video is the shared installation reference. The video shows a similar Cummins installation; use the written mounting section that matches your actual kit for bracket placement and hose routing.

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 instructions if your kit includes ZBRCKX12 or if the vehicle is not compatible with the Under-the-Hood mounting location.

Under-the-Hood — SA_LB

Use the Under-the-Hood instructions if your kit includes SA_LB and the vehicle does not have the dual-alternator/APPS-TPS conflict.

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. The black EXTREME2 housing is shown as the housing reference. Other filter-housing color options and bundled O-rings are intentionally not shown as separate gallery cards. Mounting-bracket cards are configuration-specific.

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.

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.

Installation Procedure

1. Find the Filter Housing Location

Identify the mounting configuration included with the kit and follow only the applicable mounting path.

Frame Mount — ZBRCKX12

Select a secure, serviceable frame location that allows safe hose routing and future filter service.

• Select a suitable frame mounting location as close to the oil pressure source and oil return location as practical.
• Verify the mounting location provides adequate structure for the mounting bracket and filter housing.
• Verify the pressure and return hoses can reach their connection points using the supplied hose.
• Verify adequate clearance for the filter housing, pressure and return hoses, suspension and steering components, driveline components, exhaust components, wiring, sharp edges, moving components, and excessive heat sources.
• Confirm the filter housing lid can be removed for future service.
• Inspect both sides of the frame before drilling.

Under-the-Hood — SA_LB

Compatibility Restriction: Do not use this mounting configuration on dual-alternator applications or vehicles where the APPS TPS occupies the dual-alternator mounting position.

• Locate the Under-the-Hood mounting area shown in the reference photos.
• Verify the bracket and housing location provide adequate structure, hose reach, hood clearance, and future filter service access.
• Confirm the housing lid remains accessible for future service.
• Verify clearance from surrounding hoses, wiring, belts, pulleys, cooling fan components, exhaust components, sharp edges, moving components, and excessive heat sources.

2. Find the Pressure Location

1. Locate and verify the factory oil pressure port for the vehicle.
2. Verify the supplied pressure fitting AN06-02MS is present and undamaged.
3. Verify the planned pressure-hose route before cutting the supplied hose.

3. Find the Return Location

1. Locate the engine oil filler cap.
2. Verify the supplied return components are present: FLLCCO, OCC, and AN06-02MS90.
3. Verify the planned return-hose route before cutting the supplied 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 supplied LW06BK hose ships uncut as a single 12 ft 6 in continuous length to allow flexible mounting and routing. Recommended reference lengths are approximately 7 ft and 5 ft 6 in; verify actual routing before cutting.

Under-the-Hood: The supplied LW06BK hose ships uncut as a single 7 ft continuous length to allow flexible mounting and routing. Recommended reference lengths are approximately 2 ft 7 in and 4 ft 5 in; verify final routing before cutting.

Additional Mounting Location Hose Note: If a different mounting location is selected, verify there is enough supplied hose to complete both the pressure and return routes before cutting. Additional hose is available by the foot: 3/8 Braided Nylon Hose.

Incorrect Hose Assembly Examples

Correct Hose Assembly Examples

The Complete Insane Diesel Hose & Fitting Installation Guide

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: Install one AN06-04MS90 on the filter-housing IN end and AN06-02MS on the engine-side pressure end.
    AN06-04MS90 — Pressure Hose — AN06-02MS
15. Return Hose: Install the remaining AN06-04MS90 on the filter-housing OUT end and AN06-02MS90 on the oil-filler-cap return end.
    AN06-04MS90 — Return Hose — AN06-02MS90
16. Before moving on, verify the completed pressure and return hose assemblies are correctly identified.
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 Mounting Bracket

Frame Mount — ZBRCKX12

1. Position the supplied ZBRCKX12 bracket at the selected frame mounting location and use it as a template to mark the mounting holes.
2. Before drilling, inspect both sides of the frame to verify no wiring, brake lines, fuel lines, hoses, or other 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 hole using a 21/64 in. drill bit for the supplied 3/8 in. self-threading frame mounting bolts.
6. Remove burrs, metal chips, and shavings from the drilled holes and work area.
7. Apply blue medium-strength threadlocker to the supplied 3/8 in. self-threading 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.

Under-the-Hood — SA_LB

1. Remove the radiator hose support mount from the Under-the-Hood mounting location.
2. Verify the mounting location is clean and provides adequate clearance for the completed filter housing and SA_LB bracket assembly.
3. Do not install SA_LB onto the vehicle at this time. Fully assemble the filter housing, install both hoses, and mount the completed filter housing onto SA_LB first as described in Step 8.

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 the IN side and the return hose is connected to the OUT side before mounting the housing.

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, gaskets, straight-thread sealing connections, 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

Frame Mount — ZBRCKX12

1. With both hoses already installed on the filter housing, position the assembled EXTREME2 housing onto the installed ZBRCKX12 bracket using the side mounting bosses on the filter housing.
2. Orient the housing for smooth hose routing and adequate future service access.
3. Apply blue medium-strength threadlocker to the filter housing mounting bolt threads.
4. Tighten the filter housing side mounting bolts to 35 ft-lbs.
5. Verify the bracket is securely fastened, the housing is firmly mounted, and the housing lid can be removed for future service.

Under-the-Hood — SA_LB

1. With the filter housing fully assembled and both hoses already installed, position SA_LB against the bottom threaded mounting bosses on the filter housing.
2. Orient the housing and bracket assembly for smooth hose routing, hood clearance, and adequate future service access.
3. Apply blue medium-strength threadlocker to the filter housing mounting bolt threads.
4. Install the filter housing mounting bolts through SA_LB into the bottom threaded mounting bosses and tighten to 18 ft-lbs.
5. Verify the filter housing is securely mounted to SA_LB before moving the completed assembly to the vehicle.
6. Position the completed filter housing and SA_LB bracket assembly at the Under-the-Hood mounting location.
7. Apply blue medium-strength threadlocker to the vehicle-side bracket mounting bolt threads.
8. Install the bracket mounting hardware and tighten to 35 ft-lbs.
9. Verify clearance from the radiator hose, hood, and surrounding engine components, and confirm 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 Pressure Port Fitting and Connect the Pressure Hose

1. Clean the area around the verified factory oil pressure port before removing the factory plug.
2. Remove the factory pressure-port component as required.
3. Inspect the AN06-02MS already installed on the completed pressure hose and verify the threads and sealing surfaces are clean and undamaged.
4. Apply high-quality thread sealant to the NPT threads of AN06-02MS.
5. Install the preassembled pressure-hose AN06-02MS into the verified pressure port and tighten to 110 in-lbs.
6. Verify the pressure hose is routed without kinks, twists, excessive tension, or side load on the fitting.

AN06-02MS is an NPT fitting and requires high-quality thread sealant. Tighten it to 110 in-lbs.

11. Install the Oil Filler Cap Return 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 in the O-ring groove.
2. Inspect the O-ring for cuts, cracks, deformation, or other signs of damage. Replace the O-ring if it is damaged or missing.
3. Apply a thin coat of clean engine oil to the O-ring and to the inside of the engine oil filler neck.
4. Install the FLLCCO oil filler cap onto the engine and verify the cap is fully seated.
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 FLLCCO 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.

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 OCC O-ring or its sealing surface.

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, factory pressure-port plug or fitting, radiator hose support mount when not reinstalled, mounting hardware, sealing components, and any other original components removed during installation.

Final Inspection

• Correct mounting configuration installed
• Filter housing securely mounted
• Mounting bracket securely mounted
• Pressure port fitting installed
• Oil filler cap return installed
• 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
• AN06-02MS pressure fitting installed with high-quality thread sealant and tightened to 110 in-lbs
• AN06-02MS90 return fitting installed with thread sealant and tightened to 110 in-lbs
• 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.

Oil level note: The oil level may show high if the vehicle sits for an extended period before checking.

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.