Product Information

Fig. 1: KL-0369-46 K
KL-0369-46 K Injector nozzle puller
Mercedes CDI (German Utility Model)

Suitable for Mercedes CDI engine OM 668 z.B. A-Class

Application

The KL-0369-46 K injector nozzle puller has been designed to

remove tight fitting injector nozzles installed in vehicles without
the need of removing the cylinder head.

To this purpose the injector nozzles have to be opened.

After opening, injector nozzles should never be re-used.

Fig. 2: Cylinder head support surfaces

Warnings and Notes

• Work on engines should only be performed by trained

personnel observing safety instructions and procedures
issued by the vehicle manufacturer, and using the correct
tools.

• The vehicle manufacturer’s data apply to all works done on

the vehicle.

• All specific vehicle data stated here are supplied without

commitment.

Operating instructions

Fig. 3: Unscrew the injector nozzle lock nut 1. Unscrew the valve cover screws in the support surfaces for
the extraction bridge Pos. 1* . (see Fig. 2)

2. Undo the injector nozzle fastening screws.

Note: In the CDI engines OM 668 two injection nozzles are
always fixed to a clamp. Therefore to remove just one
nozzle it is necessary to extract also the second parallel
one.

3. Disconnect the wire.

4
4. Unscrew the injector pipes.

5. Using the socket wrench Pos. 4, unscrew the injector

nozzle lock nuts (see Fig. 3) and take off the upper parts.

Note: If the socket wrench Pos. 4 does not fit the lock nut,
the wire connection may have to be twisted by using the
socket wrench until the wrench can be inserted on to the
lock nut.

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 Product Information

Fig. 4: Unscrew the ring nut

6. Remove all the injector nozzle internal parts, by means of

the wrench hexagonal insert Pos. 5 unscrew the ring nut
(see Fig. 4)
5

Fig. 5: Extraction bridge Pos. 1 assembling (Cyl. 1 and 2) 7. Pulling out the injector nozzles Cyl.1 and 2

14

7.a. Extraction bridge Pos. 1* assembly.

12

13 9 Screw the support plate Pos. 9 on the position marked

15 Cyl. 1/2 on the base plate Pos. 6 .
Fit the bolts Pos. 13, Pos. 14 and Pos. 15 on the base
6 plate Pos. 6 as shown in Fig. 5.
11

12 Note: Make sure that both the support plate Pos. 9 and
12
the bolt Pos. 13 have been correctly assembled. (see
arrow Fig. 5)

Fig. 6: Screw puller spindle Pos. 3 into the injector nozzle

7.b. Screw puller spindle into the injector nozzle.

Screw the puller spindle Pos. 3 into the injector nozzle.

(see arrow in Fig. 6)

Note: Because of the high pulling forces that are exerted, always
3 grease the spindle thread with molybdenum sulphide paste
3
KL-0014-0030.

Fig. 7: Fix extraction bridge Pos. 1

7.c. Fix the extraction bridge Pos. 1* on the cylinder head.

1
Fix the extraction bridge Pos. 1* on the cylinder head
surfaces indicated in Fig. 2. Screw collar nuts Pos. 2 on
the puller spindle Pos. 3. (see arrow in Fig. 7)

(Pos. 1* is consists of Pos. 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)

2 2

© 2007 KLANN-Spezial-Werkzeugbau-GmbH, Germany Chapter 6 6_080524.doc hu-me 2/4

 Product Information

Fig. 8: Pulling out the injector nozzles (Cyl. 1 and 2)

7.d. Pulling out the injector nozzles (Cyl. 1 and 2).

Screw uniformly both collar nuts Pos. 2 (see Fig. 8) until

both injector nozzles can be, together with their clamp,
removed from their reamed bores. (see Fig. 9)

NOTE: If necessary, prevent the puller spindle from turning, while

screwing on the collar nut.

Fig. 9: The injector nozzles have been extracted (Cyl. 1 and 2)

Injector nozzle Injector nozzle

8. Pulling out the injector nozzles Cyl. 3 and 4

Fig. 10: Extraction bridge Pos. 1 assembling (Cyl. 3 and 4)

8.a. Extraction bridge Pos. 1* assembly.
14

Screw the support plate Pos. 9 on the position marked

12 Cyl. 3/4 on the base plate Pos. 6 .
9 Fit the bolts Pos. 13, Pos. 14 and Pos. 15 on the base
plate Pos. 6 as shown in Fig. 10.
15 13
Note: Make sure that both the support plate Pos. 9 and
the bolt Pos. 13 have been correctly assembled.
6 11

12
12

8.b. Screw puller spindle into the injector nozzle.

Screw the puller spindle Pos. 3 into the injector nozzle.

Fig. 11: Screw puller spindle Pos. 3 into the injector nozzle

3 3

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 Product Information

Fig. 12: Fix extraction bridge Pos. 1.

8.c. Fix the extraction bridge Pos. 1* on the cylinder head.
Fix the extraction bridge Pos. 1* on the cylinder head
surfaces indicated in Fig. 2. Screw collar nuts Pos. 2 on
the puller spindle Pos. 3. (see arrow in Fig. 12).
1
Note: Because of the high pulling forces that are exerted, always
grease the spindle thread with molybdenum sulphide paste
KL-0014-0030.

(Pos. 1* is consists of Pos. 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)

2 2 8.d. Pulling out the injector nozzles (Cyl. 3 and 4).

Screw uniformly both collar nuts Pos. 2 until both injector
Fig. 13: Pulling out the injector nozzles
nozzles can be, together with their clamp, removed from
their reamed bores. (see Fig. 13)
Note: If necessary, prevent the puller spindle from turning, while
screwing on the collar nut.

Note
Before the new injector is installed, the fastening screw M6
thread in the cylinder head should be trimmed and cleaned by
using the thread tap KL-0369-51. If this precaution is not
taken, il will not be possible to fully tighten M6 fastening screw.
This could cause the injector nozzle to leak.

Spare Parts
Fig. 14: Spare Parts Pos. Part-No. Description Qty.
1
KL-0369-46 K Injector nozzle puller 1
consists of:
7; 8 7; 8 2 1 KL-0369-4600 Extraction bridge 1
2 KL-1383-1112 Shoulder nut 2
3 KL-0369-4606 Pull Spindle 2
6 4 KL-0369-461 A Impact Socket 1
5 KL-0369-4505 Sockets 1
KL-0369-4690 Plastic case (see Fig. 1) 1

10
Pos. Part-No. Description Qty.
1 KL-0369-4600 Extraction bridge 1
11 3 consists of:
6 KL-0369-4601 Base Plate 1
12 7 KL-0040-3005 Circlip 2
8 KL-0021-0006 Axial bearing 2
12 9 KL-0369-4603 Support plate 1
9 10 KL-0255-0011 Cylinder Pin 1
12 11 KL-0282-5106 Screw 1
15 14 13 12 KL-0206-1011 Shoulder nut 3
13 KL-0369-4605 Bolt 1
14 KL-0369-4604 Bolt 1
5 4 15 KL-0369-4602 Bolt 1

Fig. 15: Accessories: KL-0369-51

Mercedes
Accessories:
KL-0369-51 - Thread tap with drill-bit tip
Applicable e.g. for Mercedes CDI engines OM 611, 612, 613, etc.

Screw tap For recutting and cleaning the tapped hole to retain the injector nozzle
M6 holder. Important: this tool must be used before re-installing the
injector nozzle.
drill-bit tip Length:........................ 100 mm Thread: .............................. M6

© 2007 KLANN-Spezial-Werkzeugbau-GmbH, Germany Chapter 6 6_080524.doc hu-me 4/4