The Industrial Injection II901DFLY DragonFly Fuel Injector is a high-performance, drop-in HEUI fuel injector engineered specifically for 2003–2007 Ford Super Duty trucks, Excursions, and E-Series vans equipped with the 6.0L Powerstroke diesel engine. Flowing 145cc with 30% over stock extrude-honed nozzles, the DragonFly is built on factory-machined solid bodies (no welding, plugs, or failure-prone check ball modifications). Designed as a true drop-in performance upgrade, it delivers crisp throttle response, lower exhaust gas temperatures (EGTs), and cleaner atomization while remaining fully compatible with stock tuning, factory turbochargers, and standard low-pressure fuel systems.

Quick Specs & Kit Inclusions

• Application: High-performance drop-in replacement HEUI fuel injector
• Fuel Flow & Nozzle Spec: 145cc capacity / 30% over stock extrude-honed nozzle
• Horsepower Rating: Capable of supporting up to 525 HP with clean atomization
• Body Architecture: OE-factory machined solid injector body (no welded holes or check ball plugs)
• Internal Upgrades: 100% brand-new precision-fit spool valves, upgraded vented-slot coil solenoids, new plungers, and new nozzle assemblies
• Supporting Mods Required: None (operates seamlessly on stock tuning, stock fuel pressure, and factory turbochargers; regulated return not required)
• Emissions Status: Dedicated competition/racing use; check local and federal regulations
• Quantity Note: Sold individually (8 required for complete engine set; subject to refundable core charge)
• Direct Interchange Part Numbers: Industrial Injection II901DFLY, IIS-II901DFLY, 901DFLY
• What's in the Box: (1) Industrial Injection DragonFly 145cc/30% Fuel Injector, (1) Pre-Installed Viton External Body O-Ring Kit, (1) High-Pressure Oil Cushion D-Ring, and (1) Solid Copper Combustion Crush Washer

Problem Solved: Curing Spool Valve Stiction, High EGTs & Anemic Towing Power

Factory 6.0L Powerstroke HEUI injectors are notoriously prone to cold-start "stiction," where varnished oil and worn spool valves prevent the injector from firing until the engine reaches operating temperature. Furthermore, stock nozzles often struggle with fuel droplet shearing, leading to hazing and elevated exhaust gas temperatures when towing heavy loads. Cheap remanufactured performance injectors frequently feature welded bodies or modified check balls that fail under pressure, causing catastrophic internal high-pressure oil leaks. The Industrial Injection II901DFLY resolves these vulnerabilities with:

• Machined Solid Bodies: Eliminates welded ports and plugged check balls, providing structural integrity under continuous 4,000 PSI high-pressure oil loads.
• Upgraded Vented-Slot Coils & Fresh Spool Valves: Eliminates morning cold-start miss and stiction, ensuring instantaneous 48V FICM actuation.
• 30% Over Extrude-Honed Nozzles: Shortens injection duration for a cleaner, faster burn, delivering roughly 30–40 rear-wheel horsepower and immediate low-end boost spool without overwhelming stock air delivery.

Fitment

• 2003–2007 Ford F-250 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-350 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-450 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2007 Ford F-550 Super Duty 6.0L Powerstroke Turbo Diesel
• 2003–2005 Ford Excursion 6.0L Powerstroke Turbo Diesel
• 2004–2010 Ford E-Series Vans (E-350 / E-450) 6.0L Powerstroke Turbo Diesel
• 2003–2007 International / Navistar VT365 Engines

Safety & Workspace Teardown: Disconnect both negative battery cables. Remove intake ducting, upper intercooler (CAC) piping, valve covers, and the high-pressure oil rail using a dedicated socket to expose the fuel injectors. Fluid Evacuation: Suction out all pooled fuel and motor oil from the oil rail cavity and injector pocket before loosening the injector hold-down bolt to avoid hydro-locking the cylinder. Injector Extraction: Release the FICM wiring connector using a dedicated release tool. Unthread the hold-down bolt, remove the clamp, and extract the old injector using an injector puller tool. Confirm the old copper crush washer came out with the injector and did not stick to the bottom of the cup. Bore Preparation: Clean out the brass cylinder head injector cup using a dedicated bore brush and vacuum. The bottom copper seating face must be 100% bare metal, dry, and free of carbon buildup. Pre-Lube & Inspection: Verify the new Industrial Injection Viton body O-rings and copper crush washer are properly seated on the II901DFLY injector. Lightly coat the body O-rings and upper oil inlet cushion seal with clean engine oil. (Do not get oil on the copper tip washer). Injector Seating: Slide the DragonFly injector straight down into the cylinder head bore by hand, aligning the alignment dowels squarely. Apply firm downward pressure on the injector shoulder until it seats fully into the base of the cup. Hold-Down Torquing: Position the hold-down clamp over the injector shoulder and hand-thread the fastener into the cylinder head. Torque to factory specification: T40 Torx Fastener (18mm Dowel Heads): 24 ft-lbs (33 Nm) T45 Torx Fastener (20mm Dowel Heads): 26 ft-lbs (35 Nm) Final Assembly & Startup: Reinstall the high-pressure oil rail (torque oil rail bolts to 10 ft-lbs / 13 Nm), connect FICM harness plugs until the wire bails snap locked, and reinstall the valve covers. Reconnect battery terminals, cycle the ignition key (KOEO) 4 to 5 times for 30 seconds each to purge air from the fuel rails, then crank the engine to verify smooth idle and crisp throttle response.