The Bostech BT7102102 Fuel Injector Seal Kit is a premium, OEM-grade replacement reseal package engineered specifically for 2003–2010 Ford Super Duty trucks, Excursions, and E-Series vans equipped with the 6.0L Powerstroke diesel engine (as well as 4.5L LCF and International Navistar VT365 applications). Designed to service a single G2.8 HEUI fuel injector, this complete reseal kit supplies high-temperature fluorocarbon (Viton) external body O-rings, an upper high-pressure oil inlet cushion seal, and a solid copper combustion nozzle crush washer to maintain positive fluid isolation across the high-pressure oil, fuel supply, and combustion circuits.

Quick Specs & Kit Inclusions

• Application: External seal and combustion washer refresh kit for one (1) G2.8 HEUI fuel injector
• Elastomer Formulation: Premium fluorocarbon (Viton / FKM) engineered for continuous oil exposure, high thermal cycling (exceeding 250°F), and diesel fuel resistance
• Washer Construction: Solid, precision-stamped copper crush washer engineered to yield evenly under factory clamp loads
• Quantity Note: Services one (1) fuel injector; complete V8 engine reseal requires eight (8) kits total
• Emissions Status: 50-state legal (direct OE-replacement mechanical sealing kit)
• Direct Interchange Part Numbers: Bostech BT7102102, Ford 3C3Z-9229-AA, Motorcraft CM-5055, Alliant Power AP0002, Dorman 904-207, Navistar 1843682C91
• Warranty: Backed by Bostech's standard 13-month, unlimited-mileage warranty
• What's in the Box: (1) Upper Body O-Ring, (1) Lower Fuel Rail O-Ring, (1) High-Pressure Oil Inlet Cushion D-Ring Seal, and (1) Copper Combustion Tip Crush Washer

Problem Solved: Curing Crankcase Dilution, Hot No-Starts & Combustion Blow-By

Whenever a 6.0L fuel injector is pulled—whether for an injector replacement, glow plug access, or high-pressure oil rail nipple cup repair—the elastomer seals and copper washer take a permanent heat-set and cannot be safely reinstalled. Reusing old seals leads to immediate and costly failures:

• Lower Body O-Ring Breakdown: Pressurized diesel fuel (55–65 PSI) bypasses the seal into the engine crankcase, diluting motor oil with raw fuel, dropping lubricating viscosity, and wiping out main and rod bearings.
• Combustion Tip Washer Failure: High-pressure combustion gases hammer past the copper washer, scorching the lower O-ring, carbon-fouling the fuel passages, eroding the brass cylinder head cup, and pushing soot into the fuel system.
• Upper Oil Inlet D-Ring Deterioration: High-pressure engine oil leaks into the rocker carrier rather than driving the intensifier piston, resulting in extended cranking, warm-engine no-starts (ICP unable to reach the 500 PSI starting threshold), or severe power loss.

The Bostech BT7102102 kit completely resolves these failure modes by restoring factory-spec sealing integrity across all fluid barriers.

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
• 2006–2010 Ford LCF (Low Cab Forward) 4.5L V6 Diesel
• 2003–2007 International / Navistar VT365 and VT275 Engines

Safety & 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. Injector Extraction & Seal Removal: Unbolt the hold-down clamp, disconnect the FICM electrical plug, and carefully draw the injector straight out of the cylinder head. Using a brass or plastic pick, remove the old external body O-rings and top oil inlet D-ring. Remove the old copper washer from the nozzle tip (verify it did not stick to the bottom of the injector sleeve). Groove & Nozzle Cleaning: Clean the O-ring lands and nozzle body with brake cleaner and lint-free shop towels. Ensure no baked-on carbon or dirt particles remain in the sealing grooves. Bore Inspection: Thoroughly clean and inspect the brass cylinder head cup using a dedicated bore brush and vacuum. The bottom seating shoulder must be clean, dry, and bare metal to ensure the copper washer seals correctly. New Seal Installation: Lightly lubricate the new Bostech Viton body O-rings and upper oil inlet seal with clean engine oil (15W-40 or 5W-40). Roll the body O-rings into their designated upper and lower grooves without twisting or spiraling the elastomers. Seat the high-pressure oil cushion D-ring firmly into the top inlet pocket. Slide the new copper crush washer onto the injector tip, using a tiny dab of assembly grease to prevent it from sliding off during installation. Injector Insertion: Align the injector dowels and lower the injector straight into the cylinder head bore by hand. Push firmly down on the injector shoulder until it seats solidly against the bottom of the cup. Hold-Down Clamp Torquing: Position the hold-down clamp over the injector 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 & Fuel Priming: Reinstall the high-pressure oil rail (torque oil rail bolts to 10 ft-lbs / 13 Nm), connect all FICM injector harness plugs until the bails lock, 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 passages, then crank the engine and check for smooth operation.