The DTech DT600015 Fuel Injector Installation Kit (by DIPACO / DTech) is an OEM-grade external 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 International Navistar VT365 applications). Designed to service one G2.8 HEUI fuel injector during installation or service re-entry, this kit supplies high-temperature fluorocarbon (Viton) external body O-rings and a solid copper nozzle crush washer to maintain positive fluid and pressure isolation between the fuel supply rail and the combustion chamber.

Quick Specs & Kit Inclusions

• Application: External body reseal and nozzle combustion washer kit for one (1) G2.8 HEUI fuel injector
• Elastomer Grade: Premium high-temperature fluorocarbon (Viton / FKM) formulated to resist diesel fuel swelling, engine oil breakdown, and high under-valve-cover thermal cycles
• Combustion Washer: Precision-stamped, annealed solid copper crush washer designed to yield evenly under factory hold-down clamp loads
• Quantity Note: Services one (1) fuel injector; complete V8 engine reseal requires eight (8) kits total
• Emissions Status: 50-state legal (direct mechanical replacement sealing component)
• Direct Interchange Part Numbers: DTech DT600015, Dipaco DT600015, Ford 3C3Z-9229-AA, Motorcraft CM-5055, Alliant Power AP0002, Mahle GS33711, Bostech BT7102102, Navistar 1843682C91
• What's in the Box: (1) Upper Body O-Ring, (1) Lower Fuel Rail O-Ring, and (1) Solid Copper Combustion Tip Crush Washer

Problem Solved: Curing Fuel Dilution, Combustion Blow-By & Aerated Fuel Rails

Whenever an injector is removed from the 6.0L Powerstroke cylinder head, the external seals and copper crush washer take a permanent heat-and-pressure set. Reusing old, flattened, or hardened seals leads to immediate mechanical issues:

• Copper Tip Washer Failure: High-pressure combustion gas forces its way past the injector nozzle seat, scorching the lower body O-ring, carbon-fouling the fuel passages, aerating the fuel system, and eroding the brass cylinder head sleeve.
• Lower Body O-Ring Degradation: Pressurized diesel fuel (55–65 PSI) pushes past the seal into the engine crankcase, diluting motor oil, dropping viscosity, and leading to premature rod and main bearing failure.
• Upper Seal Breakdown: Allows oil and fuel cross-contamination around the rocker carrier area.

Installing the DTech DT600015 kit ensures fresh, resilient sealing barriers that restore proper cylinder compression and keep diesel fuel strictly inside the supply passages.

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
• 2004–2008 Ford F-650 / F-750 Super Duty (VT365 Diesel Engine)
• 2003–2007 International / Navistar VT365 Engines

Safety & Workspace Teardown: Turn off the ignition and disconnect both negative battery cables. Remove intake ducting, upper intercooler (CAC) piping, valve covers, and the high-pressure oil rail to expose the fuel injectors. Injector Extraction & Seal Removal: Unbolt the hold-down clamp, release the electrical harness connector, and lift the injector straight out of the cylinder head. Using a non-marring brass or plastic pick, remove the old external body O-rings. Remove the old copper washer from the nozzle tip (verify the old washer is not left behind in the bottom of the injector cup). Groove & Nozzle Cleaning: Clean the external injector body grooves and nozzle exterior thoroughly using lint-free shop towels and brake cleaner to remove dried carbon deposits and oil sludge. Bore Inspection: Thoroughly clean and inspect the cylinder head brass injector cup using a dedicated bore brush and vacuum. The bottom copper seating face must be 100% clean, dry, and bare metal to guarantee a leak-free combustion seal. New Seal Installation: Lightly lubricate the new DTech Viton body O-rings with clean engine oil (15W-40 or 5W-40). Roll the body O-rings into their designated upper and lower grooves, ensuring they are not twisted or spiraled. Slide the new copper crush washer onto the injector tip, using a tiny dab of clean assembly grease to retain it during installation. Injector Insertion: Carefully guide the injector straight down into the cylinder head bore by hand, aligning the alignment dowels squarely. Firmly press down on the injector shoulder until it seats fully against the bottom of the cup. Hold-Down Torquing: Position the hold-down clamp over the injector and hand-thread the fastener into the cylinder head. Torque to factory specification: T40 Torx Bolt (18mm Dowel Heads): 24 ft-lbs (33 Nm) T45 Torx Bolt (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 the injector harness plugs until 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 start the engine and verify smooth operation.