The AVP IRITK60 Fuel Injector Removal and Installation Tool Kit is a specialized heavy-duty service tool set engineered specifically for 2003–2007 Ford Super Duty trucks, Excursions, and E-Series vans equipped with the 6.0L Powerstroke diesel engine (as well as Navistar VT365 applications). Designed to eliminate the risk of damaging costly HEUI fuel injectors, delicate harness clips, or the cylinder head bore during service, this precision tool safely disengages the factory electrical connectors and extracts stuck, carbon-locked fuel injectors with controlled, straight-line mechanical leverage.

Quick Specs & Kit Inclusions

• Application: Specialized mechanical service tool for 6.0L Powerstroke HEUI fuel injector extraction and electrical connector release
• Material Construction: High-tensile, heat-treated alloy steel with black oxide and zinc-plated corrosion-resistant finishes
• Tool Functionality: Combines a low-profile injector body extraction pry bar/puller bridge with a dedicated connector release tool
• Head & Clearance Optimization: Low-profile geometry designed specifically to clear tight rocker carrier clearances, firewalls, and air conditioning evaporators on #7 and #8 cylinders
• Interchange References: AVP IRITK60, Ford Specialty Tool 303-1115 / 303-755, OTC 6608
• What's in the Box: (1) AVP Heavy-Duty Injector Puller/Removal Tool, (1) Precision FICM Injector Connector Release Tool, and Step-by-Step Instructions

Problem Solved: Preventing Damaged Coils, Broken Plugs & Gouged Cylinder Heads

Servicing HEUI fuel injectors on the 6.0L Powerstroke presents two notorious mechanical hurdles. First, attempting to release the fragile plastic FICM harness connector tabs with flathead screwdrivers or needle-nose pliers frequently cracks the connector body, bends the terminal pins, or shatters the plastic lock sleeves inside the rocker box. Second, due to thousands of combustion cycles and heat expansion, the copper sealing washer and carbon buildup fuse the injector body tightly into the brass cylinder head cup. Prying against the injector solenoid body with generic pry bars often bends the injector body, snaps the plastic spool valve housing, or scores the critical aluminum mating surfaces of the cylinder head. The AVP IRITK60 kit eliminates these hazards by providing a contoured release tool that compresses the electrical retention tabs squarely, alongside a matched extraction bar that applies balanced, vertical lifting force directly to the injector hold-down shoulder.

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 & Preparation: Disconnect both negative battery cables. Remove the intercooler (CAC) piping, valve covers, and high-pressure oil rail using a dedicated socket to expose the fuel injectors and rocker carrier. Fluid Extraction: Before pulling any injector, use a syringe, vacuum extractor, or fluid suction pump to thoroughly evacuate standing engine oil and fuel from around the injector body and the oil rail pocket. Connector Disconnection: Insert the AVP connector release tool into the rocker carrier pass-through hole around the injector electrical connector. Gently apply pressure to compress the retaining tabs evenly, then slide the electrical plug free from the injector body without stressing or pulling on the wires. Hold-Down Bolt Removal: Using a T40 Torx bit, unthread and remove the factory injector hold-down clamp bolt. Inspect the bolt and clamp for thread stretching or stress. Tool Engagement & Extraction: Position the slotted foot of the AVP IRITK60 injector extraction tool beneath the injector body shoulder at the hold-down pivot point. Rest the fulcrum heel squarely against the rocker arm carrier surface (placing a small shop rag or protective plate underneath to protect the casting). Apply steady, upward mechanical leverage on the tool handle to break the carbon seal and draw the injector straight up out of the cylinder head cup. Bore Cleanout & Sealing Inspection: Inspect the extracted injector tip to confirm that the old copper crush washer came out attached to the injector. If the washer remained behind, extract it from the cup using a brass pick. Use a 6.0L injector bore brush and lint-free shop cloths to clean carbon buildup and oil residue from the bottom sealing seat of the injector cup. Injector Installation & Torquing: Lubricate the new external O-rings on the replacement injector with clean engine oil and install a brand-new copper crush washer with a dab of assembly grease to hold it in place. Slide the injector down into the bore by hand, aligning the alignment dowels squarely. Reinstall the hold-down clamp and T40 Torx bolt, tightening evenly to the factory torque specification of 24 ft-lbs (33 Nm). Final Assembly & Priming: Reassemble the high-pressure oil rail (torque oil rail bolts to 10 ft-lbs / 13 Nm), reconnect the FICM injector harness plugs until locked, reinstall valve covers, and perform key-on engine-off (KOEO) fuel priming cycles before starting the engine.